Power One Aurora PVI-10.0-I-OUTD-S-400 User manual

aroruA-3.1.veR
BCB.00034.1
®is a trademark by Power-One - Product is subject to technical improvements
www.power-one.com
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Mod Number: PVI-10.0-I-OUTD-400
PVI-10.0-I-OUTD-S-400
PVI-12.0-I-OUTD-400
PVI-12.0-I-OUTD-S-400
INSTALLATION AND CONFIGURATION MANUAL
MANUALE D’INSTALLAZIONE E CONFIGURAZIONE
INSTALLATIONS UND KONFIGURATIONSMANUAL
MANUEL D'UTILISATION ET D'INSTALLATION

AURORA
Photovoltaic Inverters
INSTALLATION AND OPERATING
MANUAL
Model number: PVI-10.0/12.0-I-OUTD(-S)-400 Rev. 1.3


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TABLE OF CHANGES
Revision of
Document
Author
Date
Description of
Changes
1.0
Mastronardi F.
2011
/
06
/
01
First release
1.1
Ferrini P.
2011
/06/27
Various changes
1.
2
Statuti A.
2011
/07/13
Various changes
1.
3
Statuti A.
201
2/0
6
/1
5
Various changes
KEEP THESE INSTRUCTIONS!
IMPORTANT SAFETY INSTRUCTIONS
POWER-ONE: The total or partial reproduction of this document by any means
is forbidden without the authorization of Power-One.

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HOW TO USE THIS MANUAL
This manual contains important instructions regarding safety and operation, which must
be understood and carefully followed during the installation and maintenance of the
equipment.
In order to reduce the risk of electric shock and to be sure that the equipment is
correctly installed and ready to operate, special safety symbols are used in this manual
to highlight potential safety risks or useful information. The symbols are the following:
WARNING: Paragraphs marked by this symbol contain actions and
instructions which must be understood and followed carefully to avoid
potential harm to people.
NOTE: Paragraphs marked by this symbol contain actions and instructions
which must be understood and followed carefully to avoid damage and
malfunctions to equipment.
The equipment has various labels; those with a yellow background regard the safety
devices provided.
Make sure to have read and thoroughly understood the labels before installing the
equipment.
The symbols used are as follows:
System ground conductor (grid protection grounding, PE)
Alternating Current (AC) Value
Direct Current (DC) Value
Phase
Grounding (ground)
Attention, hot surface
Attention, risk of electric shock. Time to discharge stored energy: 5
minutes

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USEFUL INFORMATION AND SAFETY REGULATIONS
FOREWORD
The installation of AURORA must be performed in compliance with national
and local regulations.
AURORA has no spare parts.
For all kinds of maintenance or repair, please contact the authorized repair
centre closest to you. Please contact the retailer in order to find out the
location of the closest service point.
It is strongly recommended to read all the instructions contained in this
manual, and to observe the symbols displayed in the individual paragraphs
before installing or using the equipment.
Connection to the distribution grid must only occur after having received
approval from the Authority or Body in charge of the distribution of electric
energy, as is required by the current national regulations, and must be carried
out only and exclusively by qualified personnel.
The entire solar panel must be covered with a material that is opaque to
sunlight before connecting it to the appliance, as into the cables connecting it
to AURORA high voltages can occur generating conditions of serious hazard.

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GENERAL
When the inverter is operating, there can be parts that are live, or non-isolated, and
in some cases also moving or rotating, and, in addition, some surfaces may become
hot.
Unauthorized removal of required protections, improper use, faulty installation or
incorrect operation may cause serious damage to persons and things.
All operations concerning transport, installation, commissioning, and
maintenance must be carried out by qualified and trained personnel only, (all
national standards for the prevention of accidents must be respected!!!).
According to this basic safety rules, qualified and trained individuals must be
experts in the mounting, assembly, commissioning, and operation of the product,
and must and have the necessary skills, qualifications and requisites to carry out
their tasks.
ASSEMBLY
The devices must be assembled and cooled down in accordance with the
specifications outlined in the relevant documentation.
In particular, during transportation and handling, the components must not be bent,
and the isolation distances must not be changed. There must be no contact between
electronic components and connection terminals.
Electrical components must not be mechanically damaged or destroyed (potential
risk for health).
ELECTRICAL CONNECTION
When working with the live inverter, national regulations regarding accident
prevention must be respected.
Electrical installation must be carried out in accordance with the relative
regulations (e.g. conductor sections, fuses, PE connection).

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OPERATION
The system in which the inverters are installed must be equipped with further
control and protection devices, in accordance with the relative applicable safety
standards, e.g. compliance with technical equipment, accident-prevention
regulations, etc. Calibration variations are possible through the use of the
operational software. After having disconnected the inverter from the mains grid,
the live parts and the electrical connections must not be touched for a while, as
capacitors may still be charged. For this reason, all the related signs and marks
present on the devices must observed. During operation, all covers and doors must
be closed.
MAINTENANCE AND ASSISTANCE
The manufacturer’s documentation must be observed.
KEEP ALL DOCUMENTATION IN A SAFE PLACE!

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PVI-10.0/12.0-I-OUTD(-S)-400
This documentation is only valid for the aforementioned versions of the inverter.
Example of product name plate
The name plate affixed to the inverter contains the following information:
1) Manufacturer code
2) Model code
3) Serial number
4) Week/Year of production

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CONTENTS:
1 INTRODUCTION .......................................................................................11
1.1 PHOTOVOLTAIC ENERGY ............................................................... 11
2 DESCRIPTION OF THE SYSTEM............................................................12
2.1 FUNDAMENTAL ELEMENTS OF A PHOTOVOLTAIC SYSTEM:“STRINGS” AND
“ARRAYS”............................................................................................... 14
2.2 DATA TRANSMISSION AND MONITORING................................................. 16
2.3 TECHNICAL DESCRIPTION OF AURORA................................................. 16
2.4 PROTECTIONS........................................................................................ 17
2.4.1 Anti-Islanding....................................................................................... 17
2.4.2 Brand and model of photovoltaic panels................................................ 18
2.4.3 Additional protections........................................................................... 18
3 INSTALLATION.........................................................................................19
3.1 PACKAGE INSPECTION ........................................................................... 19
3.2 INSPECTING THE PACKAGE CONTENTS .................................................... 20
3.3 SELECTING THE LOCATION FOR INSTALLATION ....................................... 20
3.3.1 Wall mounting...................................................................................... 23
3.4 PRELIMINARY OPERATIONS FOR ELECTRICAL CONNECTION...................... 25
3.4.1 Procedure of CONNECTION / DISCONNECTION ............................... 26
3.4.2 Procedure for accessing the internal terminal blocks by removing the
front cover............................................................................................ 27
3.4.3 AC and DC cable selection................................................................... 28
3.4.4 Installation of the AURORA inverter..................................................... 29
3.4.5 Possible configurations of input channels.............................................. 30
3.4.5.1 Connection with independent channels............................................... 31
3.4.5.2 Parallel connection of channels.......................................................... 31
3.4.6 Connection to the AC grid..................................................................... 33
3.4.7 Connection of alarm cables and RS485 (optional)................................. 33
3.4.8 Selection of grid standard..................................................................... 34
3.4.9 Grounding of DC inputs........................................................................ 36
3.5 CR2032 LITHIUM BATTERY REPLACEMENT ........................................... 38
3.6 REPLACEMENT OF THE MEMORY ............................................................ 39
3.7 REPLACEMENT OF RS485 COMMUNICATION BOARD................................ 40

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4 COMMISSIONING AND SWITCHING OFF THE INVERTER..............41
4.1 COMMISSIONING PROCEDURE.................................................................41
4.2 START-UP USING THE SIDE BUTTON.........................................................43
4.3 SHUT-DOWN PROCEDURE .......................................................................43
5 USER INTERFACE; MONITORING AND DATA TRANSMISSION.....44
5.1 USER INTERFACE MODE..........................................................................44
5.2 DATA TYPES AVAILABLE........................................................................46
5.2.1 Real-time operational data....................................................................46
5.2.2 Data stored inside the inverter..............................................................47
5.3 LED INDICATORS ..................................................................................48
5.4 MESSAGES AND ERROR CODES................................................................52
5.5 LCD DISPLAY........................................................................................54
5.5.1 Connection of the system to the grid......................................................54
5.5.2 Error messages.....................................................................................55
5.5.3 First phase - Electric parameter check ..................................................56
5.5.4 Main menu............................................................................................60
5.5.5 Statistics...............................................................................................60
5.5.5.1 Total.................................................................................................61
5.5.5.2 Partial...............................................................................................61
5.5.5.3 Today...............................................................................................62
5.5.5.4 Last 7 days........................................................................................62
5.5.5.5 Last month........................................................................................62
5.5.5.6 Last 30 days......................................................................................63
5.5.5.7 Last 365 days....................................................................................63
5.5.5.8 User period .......................................................................................63
5.5.6 Settings.................................................................................................64
5.5.6.1 Address.............................................................................................65
5.5.6.2 Imp. Display.....................................................................................66
5.5.6.3 Service..............................................................................................67
5.5.6.4 New password...................................................................................67
5.5.6.5 Currency...........................................................................................67
5.5.6.6 Date/Time.........................................................................................67
5.5.6.7 Language ..........................................................................................67
5.5.6.8 START-UP Voltage..........................................................................68
5.5.6.9 Autotests...........................................................................................68
5.5.6.10 Alarm ..........................................................................................71
5.5.6.11 Remote Control............................................................................73
5.5.6.12 UV Prot.time................................................................................74
5.5.6.13 MPPT..........................................................................................74
5.5.6.14 Alarm Message ............................................................................75
5.5.7 Information...........................................................................................76

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5.6 AUTOTEST PROCEDURE BY USING AURORA COMMUNICATOR ............... 77
6 DATA CHECK AND COMMUNICATION...............................................82
6.1 CONNECTION THROUGH RS-485 SERIAL PORT OR RJ45 CONNECTORS ...... 82
6.1.1 RS-485 serial port................................................................................. 82
6.1.2 RJ45 connectors................................................................................... 83
6.1.3 Daisy chain .......................................................................................... 84
6.2 ACCURACY OF MEASURED VALUES ........................................................ 86
7 TROUBLESHOOTING...............................................................................88
8 TECHNICAL SPECIFICATIONS..............................................................90
8.1 INPUT VALUES....................................................................................... 90
8.2 OUTPUT VALUES ................................................................................... 93
8.3 GENERAL CHARACTERISTICS.................................................................. 94
8.4 POWER DERATING................................................................................. 96
8.5.1 Reduction in power due to environmental conditions............................. 96
8.4.1 Reduction in power due to input voltage................................................ 96

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1INTRODUCTION
This document is a technical description of the AURORA photovoltaic inverter;
the aim of this document is to provide the installer and user with the necessary
information regarding the installation, operation and use of AURORA.
1.1 PHOTOVOLTAIC ENERGY
In the energy transformation process, industrial companies (the greatest energy
consumers) have for many years now, been experimenting with ways of saving
energy and lowering pollutant emissions through the prudent and rational
consumption of known resources, and have been searching for new forms of clean
and inexhaustible energy.
Renewable energy sources provide a fundamental contribution to solving the
problem. In this context, the exploitation of solar energy to generate electrical
energy (photovoltaic) is becoming more and more important across the world.
Photovoltaic energy is a great advantage in terms of environmental protection, as
the solar radiation that we receive from the sun is directly transferred into electrical
energy without involving any form of combustion, and without producing waste
products which would pollute the environment.

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2DESCRIPTION OF THE SYSTEM
AURORA is an inverter which is capable of feeding the power supply distribution
grid with energy obtained from photovoltaic panels.
The photovoltaic panels transform energy radiated by the sun into electrical energy
in the form of direct current, or DC (through a photovoltaic field, also known as a
PV generator); to feed the distribution grid, however, and in order to make energy
available for use, it is necessary to transform it into alternating current, or AC. This
conversion, known as DC-AC conversion, is carried out in an efficient way by
AURORA, without rotating elements, only using static electronic devices.
When used in parallel with the distribution grid, the alternating current output from
the inverter flows directly into the domestic circuit, which is in turn connected to
the public distribution grid.
The solar power system supplies energy to all that which is connected to it: from
lighting to all the different domestic appliances, etc.
In the event that the energy supplied from the photovoltaic system is lower than
required, the quantity of energy necessary to guarantee the normal operation of
connected appliances will be taken from the public distribution grid. If the opposite
occurs, that is excess energy is produced, it is sent directly into the public grid, thus
becoming available to other users.
In accordance with local and National regulations, the Energy product can be sold
to the distribution grid, or credited against future consumption, thus producing
energy savings.
Available versions
PVI-12.0-I-OUTD-400
PVI-12.0-I-OUTD-S-400
PVI-10.0-I-OUTD-400
PVI-10.0-I-OUTD-S-400

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The models whose code end in -xx are equipped with an integrated DC switch
600V, 32 A, as shown in Fig. 1.
Fig. 1 - Block diagram of inverter with integrated Dc switch

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2.1 Fundamental elements of a photovoltaic system: “STRINGS” and
“ARRAYS”
In order to significantly reduce the costs of installing the photovoltaic system, costs
linked especially to the wiring problem of the inverter DC side, and to the
subsequent distribution on the AC side, the STRING technology was developed.
A photovoltaic panel is composed of many photovoltaic cells which are fixed onto
the same supporting base. A STRING is composed of a certain number of panels,
connected in series. An ARRAY is composed of one or more strings connected in
parallel.
Photovoltaic systems of a certain size can be composed of more than one array,
connected to one or more AURORA inverters.
By maximizing the number of panels inserted into each string, it is possible to
reduce the cost and complexity of the plant connection system.
Fig. 2
-
Array Composition

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WARNING: To prevent damage to equipment, the string voltage must
never exceed 520 Vdc. Due to the negative thermal coefficient of the
open circuit voltage of the photovoltaic module, maximum voltage is
obtained in conditions of minimum ambient temperature. It is advised to
check the configuration of the photovoltaic generator by means of the
AURORA Designer dimensioning software.
NOTE: A minimum Vstart input voltage of 200 Vdc (voltage can be set
from the control panel within a range of 120 Vdc to 350 Vdc) is required
in order to start the AURORA grid connection sequence. Once
connected, AURORA will transfer the available power to the grid, for
any Vdc input voltage value within the range between 70% of the value
set for Vstart, and 520V. The power transferred for each array is also
limited by the maximum manageable current (see section below) (Fig .
29 and Fig . 30 show the limits for which maximum power is
transferred).
The current of each array must also fall within the limits of the inverter. For
AURORA, the maximum current coming from each input can be 24Adc for PVI-
10.0-I, or 25 Adc for PVI-12.0-I. The PVI-10.0/12.0-I-OUTD AURORA models
can be used each for two different arrays.
In the event that the photovoltaic system exceeds the capacity of a single inverter,
other AURORA inverters can be added to the system. Each of these inverters will
be connected to an adequate section of the photovoltaic field on the DC side, and
will be connected to the distribution grid on the AC side.
Every AURORA inverter will work independently from the others, and, from its
section of photovoltaic panel, will supply the grid with the maximum available
power.
Decisions regarding the structuring of a photovoltaic system depend on a certain
number of factors and considerations, including the type of panels, the availability
of space, the future location of the plant, long-term energy production targets, etc.

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Fig. 3 - Simplified diagram of a photovoltaic system
2.2 Data transmission and monitoring
If more than one inverter is used, they may be monitored, even remotely, by using
an advanced communication system which is based on the RS-485 serial interface.
The AURORA Easy-Control system is also available as an option, and allows the
remote monitoring of the system via the Internet or a GSM modem. Furthermore, a
system of radio monitoring is also available as an option (PVI-Desktop + PVI-
Radiomodule) to obtain a remote data display terminal, connected wirelessly.
2.3 Technical description of AURORA
Fig. 1 shows the block diagram of AURORA. The main blocks are the input DC-
DC converters (known as “boosters”) and the output inverter. Both the DC-DC
converters and the output inverter work at a high switching frequency to enable a
compact design and a relatively low weight.
This version of AURORA has a high frequency transformer, i.e. a transformer with
galvanic isolation between input and output. The high frequency transformer allow
galvanic isolation between the primary (DC side) and the secondary (AC side),
maintaining very high performance in terms of energy yield and export. AURORA
is equipped with all of the protections necessary for a safe operation, in compliance
with the applicable regulations as described in the paragraph on protective devices.
AC disconnector
DC disconnector

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The block diagram shows the AURORA PVI-10.0/12.0-I-OUTD-S-400 model
with two independent converters on DC-DC input. Each of these converters is
dedicated to a separate array with an independent Maximum Power Point Tracking
(MPPT) control. This means that the two arrays can be installed in different
positions, facing in different directions. Each array is controlled by an MPPT
control circuit.
Due to the size and high efficiency of AURORA thermal dissipation system, this
inverter guarantees operation at maximum power in a wide range of ambient
temperatures.
The inverter is controlled by two independent DSPs (Digital Signal Processors),
and by a central microprocessor.
Connection to the power supply grid is thus controlled by two independent
controllers, in full compliance with the regulations current for electrical power
supply and its safety.
AURORA operating system communicates with related components in order to
carry out data analysis.
All of this ensures the optimal operation of the entire system, as well as a high
yield in all isolation and load conditions, always fully respecting the relevant
directives, laws, and regulations.
2.4 Protections
2.4.1 Anti-Islanding
In the event of a failure in the local distribution grid due to the power supply
provider, or if the machine is shut down for maintenance operations, AURORA
must be physically disconnected in a safe manner, in order to guarantee the
protection of those working on the grid, all in full compliance with the applicable
national standards and laws. In order to avoid any islanding operations, AURORA
is equipped with an automatic disconnection system, a protection known as “Anti-
Islanding”.
The AURORA PVI-10.0/12.0-I is equipped with an advanced anti-islanding
protection system, all in accordance with the relevant national standards and laws.

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2.4.2 Brand and model of photovoltaic panels
WARNING: In some cases, national and local regulations make it
obligatory for one of the DC input terminals to be connected to the
system ground. Carefully refer to the national standard in order to ground
the inverter input correctly.
A specific connector allows connecting one and only one of the two DC input
terminals (positive or negative) to the ground. A sophisticated ground protection
circuit constantly monitors the ground connection, deactivates AURORA in the
event that a ground fault is detected, and indicates the ground fault condition
through a red LED located on the front panel. The AURORA inverter is equipped
with terminals for the system ground conductors.
For further information about the grounding of terminals and protections, refer to
section 3.4.9
NOTE: For further details about disconnecting AURORA or about the
causes of malfunction, refer to paragraphs 5.3
2.4.3 Additional protections
AURORA is equipped with additional protections in order to ensure its safe
operation under any circumstances. These protections include:
continual monitoring of the grid voltage to guarantee that the voltage and
frequency values remain within the operational limits;
internal temperature control, in order to limit power automatically, should this
be necessary to ensure that the unit does not overheat (heat sink temperature
≤70°C [158°F]).
AURORA numerous control devices render its structure redundant, ensuring
the absolute safety of its operation.

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3INSTALLATION
WARNING: the electrical installation of AURORA must be performed
in compliance with the applicable local and national standards and laws.
WARNING: connecting AURORA to the electrical distribution grid may
only occur after having received authorization by the power supply
provider.
3.1 Package inspection
NOTE: The distributor delivered your AURORA to the carrier safely
packaged, and in perfect condition. By accepting the package, the carrier
assumes responsibility for its delivery. Despite careful handling by the
carrier, both the packaging and its contents may have been damaged
during transport.
The client is invited to perform the following checks:
To examine the shipping container in order to check for visible damage,
holes, cracking, or any other sign of possible damage to its contents;
To describe any damage or missing parts on the delivery documents, and to
obtain the carrier's full name and signature;
To open the shipping container and examine its contents to check for any
internal damage. When unpacking, make sure not to discard any equipment,
components, or manuals. In the event that some form of damage is detected,
contact the delivery carrier to determine the appropriate course of action. As
the carrier may request an inspection, it is important to keep all shipping
material for the inspector!
Should the inspection detect damage to the product, please contact your local
supplier or authorized distributor. They will determine whether the equipment
must be returned for repair, and will provide the relevant instructions for
doing so;
It is the client's responsibility to file a complaint with the carrier. Failure to do
so may result in the loss of all warranty service rights for any reported
damage; Keep AURORA original shipping package in case the device has to
be returned for repair.
Carefully keep the original package, as should the inverter be sent back for
repairs, the original package must be used.