Power One AURORA PVI-6000-OUTD-AU Series Setup guide

AURORA
Photovoltaic Inverters
INSTALLATION AND OPERATOR'S
MANUAL
Model number: PVI-6000-OUTD-xx-AU Rev. 1.0


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REVISION TABLE
Document
Revision
Author
Date
Change Description
1.0
First release
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 and commissioned, special safety symbols are used in this manual
to highlight potential safety risks 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 grounding protective earth,
PE)
Alternate Current (AC) value
Direct Current (DC) value
Phase
Grounding (Earth)

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USEFUL INFORMATION AND SAFETY STANDARD
FOREWORD
The installation of Aurora must be performed in full compliance with national
and local standards and regulations
AURORA has no spare parts to replace.
For any maintenance or repair please contact the nearest authorized repair
center. Please contact your reseller if you need to know the nearest authorized
repair center.
Read and understand all the instructions contained in this manual and become
familiar with the safety symbols in the relevant paragraphs before you install
and commission the equipment
The 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.
Cover the photovoltaic panels with dark opaque sheets before they are
connected to avoid any chance of high voltages to appear at the connecting
cable terminations.

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GENERAL
During inverter operation, some parts can be powered, some not properly 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 accident prevention rules in force
in the user's country must be observed ! !!).
According to these basic safety rules, qualified and trained people have skills for
the assembling, start-up and operation of the product, as well as the necessary
requirements and qualifications to perform such operations.
ASSEMBLY
Devices shall be assembled and cooled according to the specifications mentioned
in the corresponding documents.
In particular, during transport 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 prevailing national regulations on
accidents prevention.
Electrical connections shall be carried out in accordance with the applicable
regulations, such as conductor sections, fuses, PE connection.

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OPERATION
Systems with inverters shall be provided with further control and protective
devices in compliance with the corresponding prevailing 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-AU
PVI-6000-OUTD-S-AU
PVI-6000-OUTD-DS-AU
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:
1. FOREWORD.............................................................................. 11
1.1. PHOTOVOLTAIC ENERGY ..........................................................................11
2. DESCRIPTION OF THE SYSTEM......................................... 12
2.1. KEY ELEMENTS OF A PHOTOVOLTAIC SYSTEM:“STRINGS” AND “ARRAYS”.12
2.2. AVAILABLE VERSIONS.......................................................................................15
2.3. DATA TRANSMISSION AND CHECK....................................................................17
2.4. AURORA TECHNICAL DESCRIPTION................................................................17
2.5. PROTECTIVE DEVICES .......................................................................................19
2.5.1 Anti-Islanding............................................................................................19
2.5.2 Panel Ground Fault...................................................................................19
2.5.3 Further Protective Devices........................................................................19
3. INSTALLATION .......................................................................20
3.1. PACKAGE INSPECTION.......................................................................................20
3.2. INSPECTING PACKAGE CONTENTS......................................................................21
3.3. SELECTING THE PLACE OF INSTALLATION .........................................................22
3.4. WALL MOUNTING..............................................................................................23
3.5. BEFORE PERFORMING THE ELECTRICAL CONNECTIONS .....................................26
3.6. ELECTRICAL CONNECTIONS ..............................................................................30
3.7. HOW TO ACCESS THE INTERNAL TERMINAL BOARDS THROUGH THE FRONT
PANEL 34
3.8. REPLACING THE CR2032 LITHIUM BATTERY.....................................................34
3.9. REPLACING THE MEMORY .................................................................................35
4. START-UP.................................................................................. 37
5. MONITORING AND DATA TRANSMISSION..................... 38
5.1. USER’S INTERFACE MODE.................................................................................38
5.2. AVAILABLE DATA.............................................................................................40
5.2.1 Real-time operational data........................................................................40
5.2.2 Internally logged data ...............................................................................41
5.3. LED INDICATORS..............................................................................................42
5.4. MESSAGES AND ERROR CODES .........................................................................47
5.5. LCD DISPLAY...................................................................................................50
5.5.1 Connection of system to the grid ...............................................................50
5.5.2 Error messages..........................................................................................51

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5.5.3 First phase - electric parameter check...................................................... 53
5.5.4 Main menu................................................................................................. 57
5.5.5 Statistics .................................................................................................... 58
5.5.5.1 Lifetime.....................................................................58
5.5.5.2 Partial........................................................................59
5.5.5.3 Today ........................................................................59
5.5.5.4 Last 7 days ................................................................60
5.5.5.5 Last Month................................................................60
5.5.5.6 Last 30 Days .............................................................60
5.5.5.7 Last 365 Days ...........................................................60
5.5.5.8 User period................................................................61
5.5.6 Setting........................................................................................................ 62
5.5.6.1 Address .....................................................................63
5.5.6.2 Display Set................................................................63
5.5.6.3 Service.......................................................................64
5.5.6.4 New Password...........................................................64
5.5.6.5 Cash...........................................................................64
5.5.6.6 Time..........................................................................65
5.5.6.7 Language...................................................................65
5.5.6.8 START Voltage ........................................................65
5.5.6.9 Autotest.....................................................................65
5.5.6.10 Alarm ......................................................................66
5.5.6.11 Remote Control.......................................................67
5.5.6.12 UV Prot.time...........................................................68
5.5.6.13 MPPT scan..............................................................68
5.5.6.14 Scan Interval ...........................................................68
5.5.7 Info............................................................................................................ 69
6. DATA CHECK AND COMMUNICATION............................71
6.1. CONNECTION THROUGH RS-485SERIAL PORT OR RJ12 CONNECTORS .............. 71
6.1.1 RS-485 serial port..................................................................................... 71
6.1.2 RJ12 connectors........................................................................................ 72
6.1.3 Daisy chain ............................................................................................... 73
6.2. SERIAL CONNECTION WITH USB PORT.............................................................. 75
6.3. MEASUREMENT ACCURACY.............................................................................. 76

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7. TROUBLESHOOTING............................................................. 78
8. TECHNICAL FEATURES........................................................ 80
8.1. INPUT VALUES ..................................................................................................80
8.2. OUTPUT VALUES...............................................................................................83
8.3. GRID PROTECTION CHARACTERISTICS ...............................................................83
8.4. GENERAL CHARACTERISTICS.............................................................................84
8.5. POWER DERATING.............................................................................................85

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1. FOREWORD
This document contains a technical description of AURORA photovoltaic inverter
so as to provide the installer and user all the necessary information about
installation, operation and use of AURORA.
1.1. PHOTOVOLTAIC ENERGY
Industrialized countries (greater energy consumers) have been experimenting
energy-saving methods and reduced pollutant levels for many years thanks to the
energy-conversion process. This may be possible through a shrewd and rational
consumption of well-known resources, and also by looking for new forms of clean
and not exhaustible energy.
Regenerating sources of energy are fundamental to solve this problem. Under these
circumstances, solar energy exploitation to generate electrical (photovoltaic)
energy is becoming more and more important worldwide.
Photovoltaic energy, in any case, is of great advantage to the environment because
the radiated energy we receive from the sun is transformed directly into electrical
energy without any combustion process and without producing any pollution.

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2. DESCRIPTION OF THE SYSTEM
The AURORA inverter is capable of feeding a power grid using the power
generated by photovoltaic panels.
Photovoltaic panels transform the sun-radiated energy into electrical energy in the
form of direct (DC) current (through a photovoltaic field, also known as PV
generator). In order to utilize this energy and feed it back to the distribution grid,
this energy shall be turned into alternating (AC) current. Aurora does this
conversion, also known as DC to AC inversion, in a very efficient way, without
using rotating parts but just static power electronic devices.
When used in parallel with the grid, the alternate current generated by the inverter
is directly fed to the domestic distribution circuit, which is in its turn also
connected to the public power distribution grid.
The solar energy system can thus feed all the connected users, such as lighting
devices, household appliances, etc.
When the photovoltaic system is not generating sufficient energy, the power
required to ensure proper operation of connected users is taken from the public
power grid. While if the produced energy is too much, it is directly fed to the grid,
thus becoming available to other users.
According to national and local standards and regulations the produced energy can
be sold to the grid or credited to the user against future consumption, thus granting
a great saving of money.
2.1. Key elements of a photovoltaic system: “STRINGS” and “ARRAYS”
The so-called STRINGS technology has been developed in order to reduce the
installation costs of a photovoltaic system as much as possible. These costs are
mainly related to the wiring operations on inverter DC side and the consequent
distribution on the AC side.
A photovoltaic panel is composed of many photovoltaic cells assembled on the
same mount. A STRING is composed of a certain number of panels electrically
connected in series. An ARRAY is composed by one or more strings connected in
parallel.
Larger photovoltaic systems may be implemented by using several arrays
connected to one or more AURORA inverters.

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The greater the number of panels in each string, the lower the cost and the less
complex the wiring connections of the system.
Fig.2 Array Composition
WARNING: String voltage shall not exceed 600 Vdc for any reason, so
as to avoid damage to the equipment.
NOTE: A minimum input voltage of 200 Vdc is required for Aurora to
start the grid connection sequence. Once connected, Aurora will transfer
the maximum power available for any input DC voltage value in a 90V
to 580Vdc range to the grid.

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The total current of an array must also be within the capability limits of the
inverter. For AURORA, the limit is set at 18 Adc maximum for each input. The
AURORA model rated 6000W is capable of handling 2 separate arrays. The
maximum current limit for each input is 18Adc.
If the output of photovoltaic system exceeds the capacity of a single inverter,
additional AURORA inverters can be added to the system; each inverter will be
connected to an adequate section of the photovoltaic filed on the DC side and to
the grid on the AC side.
Each Aurora inverter will work independent of the others and will push to the grid
the maximum power available from its own section of the photovoltaic panels.
There are several factors and considerations to be taken into account when
designing a photovoltaic system, such as the type of panels, available room,
location, long-term target output, etc. The system configurator available on Power-
One's web site at www.power-one.com may help in sizing a photovoltaic system.
Fig.3 Simplified diagram of a photovoltaic system
DC disconnect switch
AC disconnect
switch

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2.2. Available versions
PVI-6000-OUTD-AU
PVI-6000-OUTD-S-AU
PVI-6000-OUTD-DS-AU
The identifier –S stands for integrated switch models (with a integrated DC switch
600V rated), as shown in fig. 3B
The identifier –DS stands for integrated diodes and switch models (with a
integrated DC switch 600V rated and protection diodes) , as shown in fig. 3C
In fig. 3A is shown the schematic of the model without integrated switch or diodes.
Fig. 3A –No integrated switch or diodes models
Fig. 3B - Integrated switch models

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Fig. 3C - Integrated switch and diodes models

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2.3. Data Transmission and Check
When more than one inverter is used, remote monitoring can be implemented
through a sophisticated communication system based on an RS-485 serial
interface, with a USB port 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.
2.4. AURORA Technical Description
Figure 4 shows a block diagram of AURORA. The main elements are the input
DC-DC converters (termed “boosters”) and the output inverter. Both the DC-DC
converters and the output inverter operate at high switching frequency to enable a
compact design and relatively low weight.
This is a transformer-less version of AURORA, i.e. without galvanic insulation
between input and output, which further increases conversion efficiency. On the
other hand, AURORA is equipped with the necessary protective devices to ensure
safe operation in compliance with applicable regulations without an insulation
transformer, as discussed in more detail in the relevant section.
Fig.4 Aurora block diagram

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The block diagram shows an AURORA PVI-6000-OUTD with two independent
input DC-DC converters; each converter is dedicated to a separate array with
independent Maximum Power Point Tracking (MPPT) control. This means that the
two arrays can be installed in different positions and orientations. Each array is
controlled by an MPPT control circuit.
Thanks to its high efficiency and generously sized heat sink, 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.
Aurora operative system communicates with the related parts to proceed to data
processing.
This process ensures optimal performance levels of the whole units, as well as a
high efficiency under all solar radiation and load conditions, always in full
compliance with the applicable directives, standards and regulations.

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2.5. Protective Devices
2.5.1 Anti-Islanding
When the local power distribution grid fails due to a fault or when the equipment is
shut down for maintenance operations, Aurora shall be physically disconnected
under safety conditions, so as to protect the people working on the grid, in full
compliance with the applicable prevailing national standards and regulations. To
avoid any possible islanding operation, Aurora is provided with an automatic
disconnection protective system called Anti-Islanding.
The AURORA PVI-6000-OUTD model is equipped with a state-of-the-art anti-
islanding protection system certified to the following standards and regulations:
AS4777.3-2005
2.5.2 Panel Ground Fault
This version of AURORA has been designed for use with panels with a floating
connection (positive and negative terminals not connected to ground). A
sophisticated ground protection circuit continually monitors the ground connection;
when it detects a ground fault, this circuit shuts down AURORA and turns on a 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 (step 3) for more details.
NOTE: For more details of AURORA shutdown or possible causes of
malfunction, please refer to sections 5.3 and 5.4.
2.5.3 Further Protective Devices
Aurora is equipped with additional protections to guarantee safe operation under
any circumstances. The protections include:
constant monitoring of grid voltage to ensure that voltage and frequency
remain within the specified operational limits (in accordance with standards);
automatic power limitation control based on internal temperature monitoring
to avoid overheating (heat sink temperature ≤70°C [158°F]).
Many control devices are fitted to Aurora, making its structure redundant,
but at the same time ensuring a perfect and fully safe operation.

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3. INSTALLATION
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 distributor delivered your AURORA 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, transport damage to package or its contents is always a
possibility.
The customer is encouraged to perform the following checks:
Inspect the shipping box for apparent damage, such as holes, cracking or any
sign of possible damage to its contents.
Describe any damage or shortage on the receiving documents and have the
carrier sign his/her full name.
Open 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 for the event the carrier sends an inspector
to verify damage!
If the inspection reveals damage to the 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;
It 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;
Save the original package your AURORA inverter came in, should you need
to return it for repair in the future.