Power One AURORA PVI-6000-OUT-US-W User manual

AURORA
Wind Inverters
INSTALLATION AND OPERATION
MANUAL
Model number: PVI-6000-OUT-US-W Rev. 2.0
®

User Manual Page 2 of 77
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REVISION TABLE
Document
Revision
Author Date Change Description
Rev 1.0 Nocentini
Danio
Sep.20,
2007
Rev 2.0 Mikhail
Guz
Sep. 26,
2008
Updated connection diagram,
miscellaneous changes
SAVE THESE INSTRUCTIONS!
IMPORTANT SAFETY INSTRUCTIONS
POWER-ONE: Reproduction and disclosure, even partially, of the contents of
this manual are strictly forbidden without prior authorization of
Power-One.

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IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety and operational instructions that must be
accurately understood and followed during the installation and maintenance of the
equipment.
To reduce the risk of electrical shock hazards, and to make sure the equipment is
safely installed, special safety symbols are used in this manual to highlight
potential safety hazard and important safety information. The symbols are:
WARNING: the paragraphs highlighted by this symbol contain processes
and instructions that must be absolutely understood and followed to avoid
potential danger to people.
NOTE: the paragraphs highlighted by this symbol contain processes and
instructions that must be rigorously understood and followed to avoid
potential damage to the equipment and negative results.
The equipment is provided with several labels, some of them with a yellow
background, which are related to safety issues.
Make sure to read the labels and fully understand them before installing the
equipment.
The labels utilize the following symbols:
Equipment grounding conductor (Main protective grounding, PE)
Alternate Current (AC) value
Direct Current (DC) value
Phase
Grounding (Earth)

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USEFUL INFORMATION AND SAFETY STANDARD
INTRODUCTION
¾The installation of AURORA must be performed in full compliance with
national and local standards and regulations.
¾AURORA has no spare parts to replace.
For any maintenance or repair, please, contact the nearest authorized repair
centre. Please contact your reseller if you need to know the nearest authorized
repair facility.
¾Read and understand all the instructions contained in this manual and become
familiar with the safety symbols in the relevant paragraphs before you install
the equipment
¾The connection to the distribution grid must be done only after receiving
approval from the distribution utility as required by national and state
interconnection regulations, and can be done only by qualified personnel.
¾The wind turbine need to be blocked with a mechanical brake prior to be
connected to AURORA to make sure that there is no voltage on the cable that
can result in a dangerous safety hazard.

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GENERAL
During inverter operation, some parts can be powered, some not insulated and, in
some cases, some parts can move or rotate, or some surfaces be hot.
Unauthorized removal of the necessary protections, improper use, wrong
installation or wrong operation may lead to serious damage to people and objects.
Transport, handling, installation, commissioning and maintenance must be
performed by qualified and trained personnel (all relevant accident prevention rules
must be strictly observed)
According to these basic safety rules, qualified and trained people must possess
skills required for assembly, start-up and operation of the product, and have
necessary qualifications to perform such operations.
ASSEMBLY
Devices shall be assembled and cooled according to the specifications mentioned
in the corresponding documents.
In particular, during transportation and handling, parts shall not be bent and/or the
insulation distances shall not be changed. There should be no contact between
electronic parts and connection terminals.
Electrical parts must not be mechanically damaged or destroyed (potential health
risk).
ELECTRICAL CONNECTION
With the inverter powered, comply with all national regulations on accidents
prevention.
Electrical connections shall be carried out in accordance with the applicable
regulations, such as conductor sections, fuses, PE connection, etc.

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OPERATION
Systems with inverters shall be provided with further control and protective
devices in compliance with the corresponding safety rules, such as those relating to
the compliance with technical equipment, accident-preventing regulations, etc. Any
calibration change shall be made using the operational software. Once the inverter
has been disconnected from the power grid, powered parts and electrical
connections shall not be touched as some capacitors could be charged. Comply
with all corresponding marks and symbols present on each device. During
operation, make sure that all covers and doors are closed.
MAINTENANCE AND SERVICE
Comply with manufacturer’s recommendations.
SAVE ALL DOCUMENTS IN A SAFE PLACE!

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PVI-6000-OUTD-US-W
This document applies to the above-mentioned inverters, only.
Fig.1 Name plate
The name plate affixed to the inverter provides the following information:
1) Manufacturing Part Number
2) Model Number
3) Serial Number
4) Week/Year of Manufacture

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CONTENTS:
1INTRODUCTION.................................................................. 11
2SYSTEM DESCRIPTION..................................................... 11
2.1 KEY ELEMENTS OF A WIND ENERGY SYSTEM:“WIND TURBINE” AND
“GENERATOR”..................................................................................................... 11
2.2 DATA MONITORING AND TRANSMISSION.................................................... 14
2.3 TECHNICAL DESCRIPTION.......................................................................... 14
2.4 SAFETY FEATURES .................................................................................... 15
2.4.1 Anti-Islanding ...........................................................................................15
2.4.2 Wind generator Ground Fault ..................................................................15
2.4.3 Additional saftey features .........................................................................15
3INSTALLATION ................................................................... 16
3.1 PACKAGE INSPECTION ............................................................................... 16
3.2 INSPECTING PACKAGE CONTENTS .............................................................. 17
3.3 SELECTING THE PLACE OF INSTALLATION .................................................. 18
3.4 WALL MOUNTING ...................................................................................... 19
3.5 BEFORE PERFORMING ELECTRICAL CONNECTIONS ..................................... 22
3.6 ELECTRICAL CONNECTIONS....................................................................... 25
3.7 STEP 6/6 (OPTIONAL): CONNECTION OF THE FREQUENCY SIGNAL FROM
THE WIND TURBINE. ................................................................................................. 27
3.8 HOW TO ACCESS THE INTERNAL TERMINAL BOARDS THROUGH THE
FRONT PANEL ........................................................................................................... 27
3.9 REPLACING THE CR2032 LITHIUM BATTERY ............................................. 28
3.10 REPLACING THE MEMORY.......................................................................... 29
4START UP .............................................................................. 29
5M ONITORING AND DATA TRANSMISSION................ 31
5.1 USER’S INTERFACE MODE ......................................................................... 31
5.2 AVAILABLE DATA ..................................................................................... 33
5.2.1 Real-time operational data.......................................................................33
5.2.2 Internally logged data...............................................................................34
5.3 LED INDICATORS ...................................................................................... 34
5.4 MESSAGES AND ERROR CODES.................................................................. 39

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5.5 DISPLAY LCD ........................................................................................... 42
5.5.1 Connection of system to the grid .............................................................. 42
5.5.2 Error messages......................................................................................... 43
5.5.3 First phase - electric parameter monitoring............................................. 44
5.5.4 Main menu................................................................................................ 47
5.5.5 Statistics.................................................................................................... 47
5.5.5.1 Lifetime.................................................................48
5.5.5.2 Partial ....................................................................48
5.5.5.3 Today ....................................................................49
5.5.5.4 Last 7 days ............................................................49
5.5.5.5 Last Month ............................................................49
5.5.5.6 Last 30 Days .........................................................50
5.5.5.7 Last 365 Days .......................................................50
5.5.5.8 User period............................................................50
5.5.6 Settings ..................................................................................................... 51
5.5.6.1 Address .................................................................52
5.5.6.2 Display set.............................................................52
5.5.6.3 Service...................................................................53
5.5.6.4 New password.......................................................53
5.5.6.5 Cash.......................................................................53
5.5.6.6 Time ......................................................................54
5.5.6.7 Language...............................................................54
5.5.6.8 START UP voltage ...............................................54
5.5.6.9 Autotest .................................................................54
5.5.6.10 Alarm ................................................................55
5.5.6.11 Remote control..................................................56
5.5.6.12 UV Prot.time .....................................................57
5.5.6.13 Alarm Message .................................................57
.................................................................57
5.5.7 Info............................................................................................................ 59
6DATA MONITORING AND COMMUNICATION...........61
6.1 CONNECTION THROUGH RS-485 SERIAL PORT OR RJ12 CONNECTOR ........ 61
6.1.1 RS-485 serial port..................................................................................... 61
6.1.2 RJ12 connectors ....................................................................................... 62

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6.1.3 Daisy chain...............................................................................................63
6.2 SERIAL CONNECTION WITH USB PORT....................................................... 65
6.3 MEASUREMENT ACCURACY ...................................................................... 66
7TROUBLESHOOTING......................................................... 67
8TECHNICAL FEATURES ................................................... 69
8.1 INPUT VALUES........................................................................................... 69
8.2 OUTPUT VALUE ......................................................................................... 70
8.3 GRID PROTECTION CHARACTERISTICS........................................................ 70
8.4 GENERAL CHARACTERISTICS ..................................................................... 71
8.5 POWER DERATING ..................................................................................... 72

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1INTRODUCTION
This document contains technical description of AURORA Wind inverters. It is
intended to provide the installers and users with all the necessary information about
installation, operation, and use of AURORA Wind inverters.
2SYSTEM DESCRIPTION
The AURORA inverter is capable of feeding power to the grid converting the
power generated by a wind turbine. The wind turbine (using a generator) converts
the mechanical energy from wind into the 3-phase AC voltage. The voltage and
frequency of the AC generated by the wind turbine are variable and depend on the
wind speed. To be exported to the utility grid the power need to be converted to the
frequency and voltage level of the grid.
When used in parallel with the grid, the alternate current generated by the inverter
is directly fed into the distribution circuit, which is also connected to the public
power distribution grid.
The wind energy system can thus powers all the connected users, such as lighting
devices, household appliances, etc.
When the wind turbine is not generating enough energy, the power required by the
connected users is provided by the public power grid. If the energy produced by
the wind turbine exceeds the quantity required by the user’s loads, then extra
power is directly fed to the grid, becoming available to other users.
According to national and local standards and regulations the energy produced can
be sold to the electrical utility or credited to the user against future consumption,
thus providing financial savings.
2.1 Key elements of a wind energy system: “WIND TURBINE” and
“GENERATOR”
Two elements are necessary in order to harvest the wind energy: a wind turbine
that will spin based on the wind speed and a generator.
The turbine forces the generator to rotate thus producing energy that can be
exported to the grid.
The most common turbine design has a horizontal rotor with 2 or 3 vertical
fiberglass blades forming the propeller which may have a fixed or a variable tilt.
The generator is fixed on the rotor. Usually for the small wind system a
synchronous permanent magnet generator is used. The current generated by this

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type of generators has variable voltage and frequency depending on the turbine
speed. To be exported to the grid this needs to be is converted to current.
The conversion is done in 2 steps:
A) The 3-phase AC voltage from the generator is filtered and converted to
the DC voltage. This conversion can be done inside the turbine or using
an interface box between the generator and the inverter.
B) The resulting DC output is connected to the AURORA input and
converted into AC power with the appropriate voltage and frequency to be
exported to the grid.
Fig. 2 Wind Turbine – Generator
Wind Turbine
Generator

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WARNING: The DC voltage input to the inverter shall not exceed
600Vdc for any reason, in order to avoid damage to the equipment.
NOTE: A minimum input voltage of 50Vdc is required for the AURORA inverter
to start the grid connection sequence. Once connected, the AURORA
inverter will transfer the maximum power available for any input DC
voltage value in a 50V to 580Vdc range to the grid.
The max output current from the generator or an interface device shall be always
within the inverter limits. In the AURORA inverter the total max input current is
36Adc.
Fig. 3 Wind energy system diagram
Wind
Turbine
Generator
Rectifier/
Interface
DC Voltage
A
C Voltage
AC Grid
AC disconnect
(3-pole)
DC Disconnect
(2-pole)

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2.2 Data monitoring and transmission
In system with more than one inverter, remote monitoring can be implemented
through a sophisticated communication system based on an RS-485 serial
interface. A USB port is available in the inverter to facilitate access during
installation. An optional AURORA Easy-Control system is also available for
remote monitoring via the Internet, analogue modem or GSM digital modem.
2.3 Technical Description
Figure 4 shows a block diagram of the AURORA inverter. The main elements are
the input DC-DC converters (further “boosters”) and the output DC-AC inverter.
Both the DC-DC converters and the output inverter operate at high switching
frequency to enable a compact design and relatively low weight.
Foe increased conversion efficiency, the version of the AURORA inverter does not
have a transformer therefore no galvanic isolation is provided between the input
and output. However, the AURORA inverter is equipped with the necessary safety
features to ensure safe operation in compliance with all applicable regulations
without an isolation transformer.
Fig.4 AURORA inverter block-diagram

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The block diagram shows an AURORA PVI-6000-OUTD with the two input DC-
DC converters; in the Wind version the 2 converters are always connected in
parallel.
Thanks to its high efficiency and excellent thermal design, the AURORA inverter
provides maximum power operation in a broad range of ambient temperatures.
The inverter is controlled by two independent DSPs (Digital Signal Processors)
and one central microprocessor.
This way, grid connection is controlled by two independent computers in full
compliance with electrical power supply and safety regulations.
The AURORA operating system continuously communicates with all functional
blocks and processes the data to ensure optimal performance, as well as the highest
possible efficiency under all wind speed and load conditions, always in full
compliance with the applicable directives, standards and regulations.
2.4 Safety Features
2.4.1 Anti-Islanding
When the local power distribution grid fails or when it is shut down for
maintenance, the AURORA inverter shall be disconnected from the grid, to protect
the people working on the grid, and in full compliance with the applicable national
standards and regulations. To avoid any possible islanding operation, the
AURORA inverter is equipped with the automatic disconnection protective system
called Anti-Islanding. The AURORA PVI-6000-OUTD-US-W model is equipped
with a state-of-the-art anti-islanding protection system certified to the following
standards and regulations:
¾UL 1741 standard
2.4.2 Wind generator Ground Fault
A sophisticated ground protection circuit continually monitors the ground
connection. When a ground fault is detected, this circuit shuts down the AURORA
inverter and turns on the red LED on the front panel to indicate a ground fault
condition. The AURORA inverter is equipped with a terminal for the system
grounding conductor; see section 3.6 for more details.
NOTE: For more details regarding the AURORA shutdown or possible
causes of malfunction, please, refer to sections 5.3 and 5.4.
2.4.3 Additional saftey features
The AURORA inverter is equipped with additional protections to guarantee safe
operation under any circumstances. The protections include:

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¾constant monitoring of the grid voltage to ensure that voltage and frequency
remain within the specified limits (in accordance with the UL 1741 standard);
¾automatic power limit based on internal temperature monitoring to avoid
overheating (heat sink temperature ≤70°C [158°F]).
The redundancy of safety features implemented in the AURORA inverter
guarantees completely safe operations under any conditions
3INSTALLATION
WARNING: The electrical installation of AURORA must be performed
in compliance with applicable local and national standards and laws.
WARNING: The connection of AURORA to the electrical distribution
grid must be performed only after receiving authorization from the utility
that operates the grid
3.1 Package Inspection
NOTE: The shipper delivered your AURORA inverter to the carrier
safely packaged and in perfect condition. Upon acceptance of the package,
the carrier assumes responsibility for its safe delivery. In spite of careful
handling during transportation, damage to package or its contents
sometimes occurs.
The customer is encouraged to perform the following checks:
¾Inspect the shipping box for apparent damage, such as holes, cracking, or any
signs of possible damage to its contents.
¾Record any damage or shortage in the receiving documents and have the
carrier sign his/her full name.
¾Open the shipping box and inspect the contents for internal damage. While
unpacking, be careful not to discard any equipment, parts or manuals. If any
damage is detected, call the delivering carrier to determine the appropriate
action. Save all shipping material in case the carrier should send an inspector
to verify damage!
¾If the inspection reveals damage to the AURORA inverter, call your supplier,
or authorized distributor. They will determine if the equipment should be
returned for repair. They will also provide instructions on how to get the
equipment repaired.
¾It is the customer's responsibility to file a claim with the carrier. Failure to file
a claim with the carrier may void all warranty service rights for any damage.

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¾Save the original package your AURORA inverter arrived in for use in case
you should need to return it for repair in the future.
3.2 Inspecting package contents
Description Quantity
Inverter AURORA 1
Bag containing:
6.3x70 screws 3 pc.
3 SX10 wall anchors 3 pc.
Torx20 wrench 1 pc
M6x10 screw 1 pc
d.18 washer 1 pc
1
Copy of this manual 1
Certificate of warranty 1
CD-ROM with communication software 1

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3.3 Selecting the place of installation
The installation place should be selected based on the following considerations:
¾Height from ground level should be enough to ensure that display and status
LEDs are easy to read.
¾Select a well ventilated place sheltered from direct sun radiation. Choose a
place that allows unobstructed airflow around the unit.
¾Allow sufficient room around the unit to enable easy installation and removal
from the mounting surface.
¾A door is provided on the unit’s front panel for hardware maintenance purpose.
The USB port for software connection is on the right side of the inverter
(protected by a cover); installation should provide free access to this side,
otherwise you will have to remove the unit from its mounting surface during
maintenance operations.
The following figure shows the recommended minimum clearances around the
inverter:
<<
Fig.5. Minimum clearances around AURORA inverter
8”
6”
6”2”

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3.4 Wall mounting
AURORA should be mounted in a vertical position as shown in Fig.6.
The package includes a hardware kit with three 6.3x70 steel screws and 3 SX10
wall anchors for installation of a metal bracket to a masonry wall. Screws and wall
anchors can be installed using 3 of the 5 holes available on the bracket (reference
part C in the pictures below).
WARNING: Bracket shall be mounted vertically on wall: spring side
shall face up, while side with M6 PEM shall face down.
Since the wall can be made from different construction materials, it is the installer's
responsibility to provide suitable mounting hardware. We recommend using
stainless steel screws.
For concrete wall mounting the hole should be min. 8 mm in diameter and min. 70
mm deep.
Hang AURORA on the spring at the bracket top, by means of the metal mount
fastened to the upper part at inverter back. The central part of this plate features a
seat for fastening the spring (see Part A in Fig. 6).
Once inverter top end is secured in place, you need to secure its bottom end.
From inverter front, use an M6x10 screw and washer to secure the unit to the
bracket PEM, starting with the center slot of the lower plate (Part B in Fig. 6).
FRONT BACK
Part.A
Part.B

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Fig.6. AURORA wall mounting
NOTE: Ensure that the AURORA inverter is not exposed to direct sun radiation
or other external heat sources, including the units installed underneath it
(see Fig. 7). If several inverters are stacked up, the heat generated by the
inverters placed at the bottom of the stack could cause ambient
temperature to rise and affect the operation of the inverters in the upper
rows. Temperatures exceeding 40°C could result in the derating of the
output power of the units placed in the upper rows.
A combination of high output power and high ambient temperature will
result in a significant power derating and a lower energy production. For
proper cooling, make sure to install AURORA to allow unobstructed air
flow (for instance, the front panel should never face a solid surface).
Part.A
Part.B
Part.C
Part.D