Power One Aurora PVI-3.8/4.6-I-OUTD User manual

AURORA
Photovoltaic Inverters
INSTALLATION AND OPERATING
MANUAL
Model number: PVI-3.8/4.6-I-OUTD Rev. 1.5


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TABLE OF CHANGES
Revision of
Document Author Date Description of changes
1.0
Mastronardi F.
03/08/10 First release
1.1
Mastrona
rdi F.
17/05/11 First review
1.2
Statuti A.
30/06/11 Second review
1.3
Brogi D.
06/07/11 Third review
1.4
Statuti A.
18/07/12 Fourth review
1.5
Statuti A.
26/11/12 Fifth review
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 earth conductor (grid protection earth, PE)
Alternating Current (AC) Value
Direct Current (DC) Value
Phase
Grounding (ground)
Caution, hot surface
Danger, 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 inverters must be performed in compliance with
national and local regulations.
The AURORA inverter 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 an opaque material before connecting
it to the appliance, as high voltages can occur in the connecting cables 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-3.8-I-OUTD
PVI-3.8-I-OUTD-S
PVI-4.6-I-OUTD
PVI-4.6-I-OUTD-S
This documentation is only valid for the aforementioned inverter versions
Product name plate (PVI-4.6-I-OUTD-S)
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 THE AURORA INVERTERS ......................... 16
2.4 PROTECTIONS........................................................................................ 17
2.4.1 Anti-Islanding....................................................................................... 17
2.4.2 Ground fault/RCD protection................................................................ 18
2.4.3 Additional protective devices ................................................................ 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 wire 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........................................................... 34
3.4.7 Connection of alarm cables and RS485 (optional)................................. 35
3.4.8 Selection of grid standard..................................................................... 35
3.4.9 Grounding of DC inputs........................................................................ 37
3.5 CR2032 LITHIUM BATTERY REPLACEMENT ........................................... 39
3.6 REPLACEMENT OF THE MEMORY ............................................................ 39
3.7 REPLACEMENT OF THE RS485 COMMUNICATION BOARD ......................... 40
4 COMMISSIONING AND SWITCHING OFF THE INVERTER.............. 41
4.1 START-UP PROCEDURE........................................................................... 41
4.2 START-UP USING THE SIDE BUTTON ........................................................ 43

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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................................................................53
5.5 LCD DISPLAY........................................................................................55
5.5.1 Connection of the system to the grid.......................................................55
5.5.2 Error messages .....................................................................................57
5.5.3 First phase - Electric parameter check...................................................57
5.5.4 Main menu............................................................................................61
5.5.5 Statistics................................................................................................62
5.5.5.1 Total........................................................................................62
5.5.5.2 Partial......................................................................................63
5.5.5.3 Today......................................................................................63
5.5.5.4 Last 7 days ..............................................................................64
5.5.5.5 Last month ..............................................................................64
5.5.5.6 Last 30 days ............................................................................64
5.5.5.7 Last 365 days...........................................................................65
5.5.5.8 User period..............................................................................65
5.5.6 Settings.................................................................................................66
5.5.6.1 Address...................................................................................67
5.5.6.2 Imp. Display............................................................................67
5.5.6.3 Service ....................................................................................68
5.5.6.4 New password.........................................................................68
5.5.6.5 Currency..................................................................................68
5.5.6.6 Date/Time ...............................................................................69
5.5.6.7 Language.................................................................................69
5.5.6.8 START-UP Voltage.................................................................69
5.5.6.9 Autotest Operation...................................................................69
5.5.6.10 Alarm......................................................................................72
5.5.6.11 Remote Control .......................................................................74
5.5.6.12 UV Prot.time...........................................................................74
5.5.6.13 MPPT......................................................................................75
5.5.6.14 Alarm Message........................................................................75
5.5.7 Info.......................................................................................................77
5.6 AUTOTEST PROCEDURE BY USING AURORA COMMUNICATOR.......78

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6 DATA CHECK AND COMMUNICATION............................................... 83
6.1 CONNECTION THROUGH RS-485 SERIAL PORT OR RJ45 CONNECTORS ...... 83
6.1.1 RS-485 serial port................................................................................. 83
6.1.2 RJ45 connectors................................................................................... 84
6.1.3 Daisy chain .......................................................................................... 84
7 TROUBLESHOOTING............................................................................... 86
8 TECHNICAL SPECIFICATIONS.............................................................. 88
8.1 INPUT VALUES....................................................................................... 88
8.2 OUTPUT VALUES ................................................................................... 91
8.3 GENERAL CHARACTERISTICS.................................................................. 92
8.4 POWER DERATING................................................................................. 94

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1INTRODUCTION
This document is a technical description of the AURORA photovoltaic inverter; the
aim of the document is to provide the installer and user with the necessary information
regarding the installation, operation and use of AURORA photovoltaic inverters.
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 increasingly 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 the
AURORA inverters, 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-3.8-I-OUTD
PVI-3.8-I-OUTD-S
PVI-4.6-I-OUTD
PVI-4.6-I-OUTD-S

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The models whose code ends in -S are supplied with an integrated DC switch 600 V,
25A as shown in Fig. 1.
Fig. 1 - Block diagram of inverter with integrated DC switch
The models whose code does not end in -S are supplied without the 600V integrated
switch.
600Vdc/25A
600Vdc/25A
600Vdc/25A
600Vdc/25A
GNDMODE
PTC+
PTC-
GND MODE
PTC+
PTC-
GND MODE
FUSE+
FUSE-
PTC
MAIN GROUND
+IN2 -IN2
+PV_IN2 -PV_IN2
+IN1 -IN1
+PV_IN1 -PV_IN1
ON
OFF
Switch Knob
EMI FILTERCH2 EMI FILTERCH1
AC EMI FILTER
1 2
GRID TERMINAL BLOCKS
3
INPUT TERMINAL BLOCK
BOOST CH2 BOOST CH1
AURORA INVERTER
INPUT/OUTPUT BOARD CAPS
BOARD
BOOST CH2 BOARD
BOOST CH1 + INVERTER BOARD
INVERTER
LOGIC CONTROL BOARD
DISPLAY / KEY BOARD
AUX INTERNAL SUPPLY
BRIDGE RECTIFIER BRIDGE RECTIFIER
COUNTRY SEL.
+5V
positive grounding negative grounding
GFCI & COUNTRY SEL.

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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
Fig. 2 Array composition
PV Panel
PV String
PV Array
PV Cell
+
+
_
_
+
_

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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 the range of 120 Vdc to 350 Vdc) is required
in order to start the AURORA inverter grid connection sequence. Once
connected, the inverter 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 paragraph below) (Figure 28 and
Figure 29 show the limits for which maximum power is transferred).
The current of each array must also fall within the limits of the inverter. For the
AURORA inverters, the maximum current coming from each input can be 14Adc for
PVI-4.6-I-OUTD models, or 12.5 A for PVI-3.8-I-OUTD models.
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.
On the Power-One website (www.power-one.com) a configuration program is
available to help you dimensioning your photovoltaic system (AURORA Designer).

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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 additional form of monitoring,
and allows for the remote monitoring of the system via the Internet or digital GPRS
modem. Furthermore, a system of radio monitoring is also available as an option (PVI-
Desktop + PVI-Radio module) to obtain a remote data display terminal, connected
wirelessly.
2.3 Technical description of the AURORA inverters
Fig. 1 shows the block diagram of an AURORA inverter. 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 inverter 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. The
AURORA inverters are equipped with all of the protections necessary for a safe
DC disconnect
switch
AC disconnect
switch

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operation, in compliance with the applicable regulations as described in the paragraph
on protective devices.
The block diagram shows the PVI-3.8/4.6-I-OUTD 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 the AURORA inverters and the thermal
dissipation system, operation at maximum power in a wide range of ambient
temperatures is guaranteed.
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 current regulations for electrical power supply and its
safety.
The AURORA inverter operating system communicates with related components in
order to carry out data analysis.
All of this ensures the optimal operation of the entire system and 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, the inverter 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, the inverter is equipped with an
automatic disconnection system, a protection known as “Anti-Islanding”.
The PVI-3.8/4.6-I-OUTD model 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 Ground fault/RCD protection
WARNING: In some cases, national and local regulations make it obligatory
to connect one of the DC input terminals to the system ground. Carefully
refer 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 the inverter 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 the AURORA inverters or
about the causes of malfunction, refer to paragraphs 0
2.4.3 Additional protective devices
The AURORA inverters are 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 it be
necessary to ensure that the unit does not overheat (heat sink temperature ≤70°C
[158°F]).
The numerous control devices create a redundant structure, ensuring the
absolute safety of its operation.

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3INSTALLATION
WARNING: the electrical installation of the AURORA inverters must be
performed in compliance with the applicable local and national standards and
laws.
WARNING: connecting the AURORA inverters to the power supply
distribution grid may only occur after having received authorization by the
utility operating that grid.
3.1 Package inspection
NOTE: The distributor delivered your AURORA inverter 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 original shipping package in case the device has to be returned for repair.

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3.2 Inspecting the package contents
Description
Quantity (No.)
AURORA Inverter
1
Bag containing:
4 screws 6.3x70, 4 SX10 anchors, Torx20
screwdriver, 1 screw 6x10, 5 washers d. 18, 2
counterparts for signal connectors (3 poles), 2
counterparts for signal connectors (8 poles)
1
Bracket for wall mounting
1
Copies of this manual
1
Certificate of warranty
1
CD
-
ROM with communication software
1
3.3 Selecting the location for installation
The inverter must be installed in a location chosen according to the following
considerations:
The inverter must be placed at a height from ground level, so that the display and
status LEDs can be read easily.
Choose a location which is protected from direct sunlight and is well-ventilated.
Avoid locations where air is unable to circulate freely around the unit.
Leave enough room around the unit to allow for easy installation and removal from
the mounting surface.
Hardware and software maintenance is carried out through the cover on the front of
the inverter. It is thus necessary to have easy access to this side, if you do not wish
to remove the unit from its mounting surface.
The figure below indicates minimum clearances that must be maintained around
the inverter: