Power One AURORA PVI-OUTD-US Series Setup guide

AURORA
Photovoltaic Inverters
INSTALLATION AND OPERATOR'S
MANUAL
Note: This document contains proprietary information of Power-One, Inc. The
contents of this document or any part thereof should not be reproduced or
disclosed to any third party without Power-One's express written consent.
Model number: PVI-3.0/3.6/4.2-OUTD-x-US Rev. 2.1
®

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REVISION TABLE
Document
Revision
Date Change Description
1.0 19-Nov-07
1.1 12-Jan-09
2.0 17-Mar-09 Certificate of Compliance added
2.1 26-Jun-09 Modified allowed cable section according to
normative
SAVE THESE INSTRUCTIONS!
IMPORTANT SAFETY INSTRUCTIONS

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IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety instructions that must be followed during the
installation and startup of the equipment. To reduce the risk of electrical shock hazards
and to ensure the equipment is safely installed prior to operation, special safety
symbols are used in this manual to highlight potential safety hazards and provide
important safety information. The symbols are:
WARNING: The paragraphs highlighted by this symbol contain processes
and instructions that must be followed to avoid potential injury to personnel
and equipment damage..
NOTE: The paragraphs highlighted by this symbol contain processes and
instructions that must be followed to avoid potential equipment damage or
negative results.
•The equipment is provided with several labels. Labels with a yellow background
are related to safety issues.
•Read the labels and ensure that you understand them before performing
equipment installation.
•The labels utilize the following symbols:
Equipment grounding conductor (Main grounding protective earth,
PE)
Alternating Current (AC) value
Direct Current (DC) value
Phase
Grounding (Earth)

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USEFUL INFORMATION AND SAFETY STANDARDS
FOREWORD
•Installation of the Aurora inverter must be performed in full compliance with
national and local standards and regulations.
•The Aurora inverter has no user-serviceable parts. For maintenance or service
please contact Power-One Customer Service.
•Read the instructions contained in this manual and become familiar with the
safety symbols in the relevant paragraphs before you install and operate the
equipment.
•Connection to the distribution grid must be done only after receiving approval
from the appropriate local distribution utility as required by national and state
interconnection regulations, and must be done only by qualified personnel.
•Cover the photovoltaic panels with dark opaque sheets before they are connected.
This helps prevent any hazardous high voltages from appearing at the connecting
cable terminations.
GENERAL
•During inverter operation, parts may be powered, may lose proper insulation, and
may move. In addition, some surfaces may become hot.
•Unauthorized removal of necessary protections, improper use, poor or incorrect
installation, or improper operation may lead to serious injury to people and/or
equipment damage.
•Transportation, handling, installation, startup, and maintenance must be
performed by qualified and trained personnel (all accident prevention rules in
force in the user's country must be observed!).
•Basic safety rules require using qualified and trained personnel that have the skills
for assembly, startup, and operation of the product to perform such activities.

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ASSEMBLY
•Devices should be assembled and cooled according to the specifications
mentioned in their corresponding documents.
•In particular, during transport and handling, parts should not be bent and/or the
insulation distances should not be changed. There should be no contact between
electronic parts and connection terminals.
•Electrical parts must not be mechanically damaged or destroyed (this could cause
potential health risks).
ELECTRICAL CONNECTION
•Always comply with all prevailing national accident-prevention regulations.
•Electrical connections such as conductor sections, fuses, PE connection, etc., must
always be made in accordance with applicable regulations..
OPERATION
Systems with inverters should be provided with additional control and protective
devices in compliance with the corresponding prevailing safety rules, such as those
relating to the compliance with technical equipment, accident-prevention regulations,
etc.
•Comply with all corresponding marks and symbols present on each device.
•Ensure that all covers and doors are closed during operation.
•Any calibration changes should be made using the operational software.
•Anytime that the inverter has been disconnected from the power grid, powered
parts and electrical connections should not be touched as some capacitors could
still be charged.
MAINTENANCE AND SERVICE
Contact Power-One Customer Service for maintenance and service needs.
SAVE ALL DOCUMENTS IN A SAFE PLACE!

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This document applies only to the PVI-3.0-OUTD-US, PVI-3.6-OUTD-US,
PVI-4.2-OUTD-US, PVI-3.0-OUTD-S-US, PVI-3.6-OUTD-S-US, PVI-4.2-
OUTD-S-US inverters.
Fig. 1 - Name Plate for PVI-4.2-OUTD-US
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
1FOREWORD ...............................................................................10
1.1 PHOTOVOLTAIC ENERGY ...................................................................10
2SYSTEM DESCRIPTION..........................................................11
2.1 KEY ELEMENTS OF A PHOTOVOLTAIC SYSTEM:“STRINGS” AND
“ARRAYS” .............................................................................................................13
2.2 DATA TRANSMISSION AND CHECK.............................................................15
2.3 AURORA TECHNICAL DESCRIPTION ...........................................................15
2.4 PROTECTIVE DEVICES ................................................................................16
2.4.1 Anti-Islanding........................................................................................16
2.4.2 Panel Ground Fault...............................................................................16
2.4.3 Additional Protective Devices................................................................17
3INSTALLATION.........................................................................18
3.1 PACKAGE INSPECTION................................................................................18
3.1.1 Inspecting package contents..................................................................19
3.2 SELECTING THE INSTALLATION LOCATION .................................................19
3.3 BEFORE PERFORMING THE ELECTRICAL CONNECTIONS.............................24
3.3.1 Switch Box ELECTRICAL CONNECTING and/or DISCONNECTING
procedure............................................................................................................26
3.3.2 Removing the Front Cover and Accessing the Internal Terminal Block.
28
3.3.3 Aurora Switch Box Description.............................................................29
3.3.4 AURORA Inverter Typical Electrical Installations................................34
3.3.5 Possible Aurora DC Input Configuration..............................................35
3.3.5.1 Aurora Inverter - Connection to a Single Photovoltaic
Array 36
3.3.5.2 Parallel Connection of the Aurora DC inputs............37
3.3.6 Connection to the AC GRID ..................................................................40
3.3.7 Connection of RS485 and Alarm contact...............................................42
3.4 DISCONNECTING THE AURORA INVERTER FROM THE DC SWITCH...........46
3.4.1 ELECTRICAL DISCONNECTION OF THE INVERTER FROM THE
SWITCH BOX PROCEDURE.............................................................................46
3.5 CR2032 LITHIUM BATTERY REPLACEMENT ..............................................48
4START-UP ...................................................................................49

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5MONITORING AND DATA TRANSMISSION......................51
5.1 USER’S INTERFACE MODE ......................................................................... 51
5.2 AVAILABLE DATA ..................................................................................... 54
5.2.1 Real-time operational data....................................................................54
5.2.2 Internally logged data ...........................................................................55
5.3 LED INDICATORS ...................................................................................... 56
5.4 MESSAGES AND ERROR CODES.................................................................. 59
5.5 LCD DISPLAY ........................................................................................... 62
5.5.1 Connection of the system to the grid .....................................................62
5.5.2 Error messages......................................................................................63
5.5.3 First phase - electric parameter check..................................................64
5.5.4 Main menu.............................................................................................67
5.5.5 Statistics ................................................................................................68
5.5.6 Information............................................................................................68
5.5.6.1 Lifetime ..................................................................... 68
5.5.6.2 Partial......................................................................... 69
5.5.6.3 Today......................................................................... 69
5.5.6.4 Last 7 days................................................................. 69
5.5.6.5 Last Month ................................................................ 70
5.5.6.6 Last 30 Days.............................................................. 70
5.5.6.7 Last 365 Days............................................................ 70
5.5.6.8 User period ................................................................ 70
5.5.7 Settings..................................................................................................72
5.5.7.1 Address...................................................................... 73
5.5.7.2 Display Set ................................................................ 73
5.5.7.3 Service ....................................................................... 74
5.5.7.4 New Password ........................................................... 74
5.5.7.5 Cash ........................................................................... 74
5.5.7.6 Time........................................................................... 74
5.5.7.7 Language ................................................................... 75
5.5.7.8 Start-up Voltage......................................................... 75
5.5.7.9 Autotest ..................................................................... 75
5.5.7.10 Alarm..................................................................... 76
5.5.7.11 Remote Control ..................................................... 77
5.5.7.12 UV Prot. time......................................................... 78
5.5.7.13 MPPT scan ............................................................ 78

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5.5.7.14 Scan Interval ..........................................................78
5.5.8 Info.........................................................................................................79
6DATA CHECK AND COMMUNICATION.............................81
6.1 CONNECTION THROUGH RS-485 SERIAL PORT OR RJ12 CONNECTORS .......81
6.1.1 RS-485 serial port..................................................................................81
6.1.2 RJ12 connectors.....................................................................................84
6.1.3 Daisy chain............................................................................................85
6.2 SERIAL CONNECTION WITH USB PORT .......................................................87
6.3 ALARM CONTACT CONNECTION .................................................................87
6.4 MEASUREMENT ACCURACY.......................................................................88
7TROUBLESHOOTING..............................................................89
8TECHNICAL FEATURES.........................................................91
8.1 INPUT VALUES ...........................................................................................91
8.2 OUTPUT VALUES ........................................................................................94
8.3 GRID PROTECTION CHARACTERISTICS ........................................................95
8.4 GENERAL CHARACTERISTICS .....................................................................95
8.5 BACKFEED CURRENT .................................................................................98
8.6 VOLTAGE AND FREQUENCY LIMITS ............................................................99
8.7 FAULT CURRENT......................................................................................100
8.8 POWER DERATING ...................................................................................101

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1FOREWORD
This document contains a technical description of the Aurora Photovoltaic Inverter
which provides the installer and user with the information required for its installation,
operation, and use.
1.1 PHOTOVOLTAIC ENERGY
Industrialized countries (greater energy consumers) have been experimenting with
energy-saving methods and the reduction of 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
non-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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2SYSTEM DESCRIPTION
The Aurora inverter feeds a power grid by using the power generated from
photovoltaic panels. The photovoltaic panels transform sun-radiated energy into
electrical energy in the form of direct current (DC) through a photovoltaic field (also
known as a PV generator). In order to utilize this energy and feed it to the distribution
grid, the energy needs to be converted into alternating current (AC). The Aurora
inverter does this conversion, also known as DC to AC inversion, very efficiently
using just static power electronic devices and without the need of rotating parts.
When used in parallel with the power grid, the alternating current generated by the
inverter is directly fed to the domestic distribution circuit, which in turn is also
connected to the public power distribution grid. The solar energy system can thus feed
all the connected user electrical loads, 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 user loads is taken from the public power grid.
While, if the produced energy exceeds load needs, it is directly fed to the grid, thus
becoming available to other users' loads.
According to national and local standards and regulations, the user-produced energy
can be sold to the grid or credited to the user against future consumption, thus
reducing costs and providing what could even be significant savings.
Available versions
PVI-3.0-OUTD-US
PVI-3.6-OUTD-US
PVI-4.2-OUTD-US
PVI-3.0-OUTD-S-US
PVI-3.6-OUTD-S-US
PVI-4.2-OUTD-S-US

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The S-US models are provided with an integrated 600V, 25A DC switch as shown on
fig. 1a.
Fig.1a – Schema funzionale inverter con DC switch integrato.
Fig. 1b - Block diagram of inverters model without integrated DC switch

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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 the inverter's 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 of two or more strings electrically connected in parallel.
Larger photovoltaic systems may be implemented by using several arrays connected
to one or more Aurora inverters.
The greater the number of panels in each string, the lower the cost and the less
complex the wiring connections of the system.
PV Panel
PV String
PV Array
PV Cell
+
+
_
_
+
_
Fig. 2 - Array Composition

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WARNING: To avoid equipment damage, the string voltage must not exceed 600 Vdc
for any reason.
NOTE: A minimum input voltage of 200 Vdc is required for the Aurora
inverter to start the grid connection sequence. Once connected, the inverter
will transfer the maximum available power for any DC input voltage value
within a 90 Vdc to 580 Vdc range to the grid.
The total current of an array must also be within the capability limits of the inverter.
For PVI-4.2 model, the limit is set at 16 Adc maximum for each input, while for PVI-
3.0/3.6 models the limit is set at 10 Adc maximum for each input. The AURORA is
capable of handling 2 separate arrays.
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 field on the DC side and to the grid on the
AC side.
Each Aurora inverter will work independent of the others and will push the maximum
power available from its own section of the photovoltaic panels to the grid. There are
several factors and considerations to be taken into account when designing
photovoltaic systems, such as the type of panels, available space, 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

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2.2 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, analog modem, or
GSM digital modem.
2.3 Aurora Technical Description
Figure 4 shows a block diagram of the Aurora inverter. 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 a high switching frequency to enable a
compact design and relatively low weight.
This is a transformerless version of the Aurora, i.e. without galvanic insulation
between input and output, which further increases conversion efficiency. On the other
hand, the Aurora inverter is equipped with the necessary protective devices to ensure
safe operation in compliance with applicable regulations without an insulation
transformer. These protections are discussed in more detail in sections 2.4 through
2.4.3.
Fig. 4 - Aurora Inverter Block Diagram

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The block diagram shows an Aurora PVI-3.0/3.6/4.2-OUTD-US 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 a 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 Digital Signal Processors (DSPs) 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 inverter operating 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, while
always in full compliance with the applicable directives, standards, and regulations.
2.4 Protective Devices
2.4.1 Anti-Islanding
When the local power distribution grid fails due to a fault or when the equipment is
shut down for maintenance operations, the Aurora inverter should be physically
disconnected under safety conditions, so as to protect any personnel working on the
grid, in full compliance with the applicable prevailing national standards and
regulations. To avoid any possible islanding operation, the Aurora inverter is provided
with an automatic disconnection protective system called Anti-Islanding.
The AURORA PVI-3.0/3.6/4.2-OUTD-US model is equipped with a state-of-the-art
anti-islanding protection system certified to the following standards and regulations:
•CSA-C22.2 N.107.1-01 UL Std N.1741
2.4.2 Panel Ground Fault
The Aurora PVI-3.0/3.6/4.2 versions have 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 the inverter 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 3.3.6 (steps
3 and 4) for more details.
NOTE: For more details of Aurora inverter shutdown or possible causes of
malfunction, please refer to sections 5.3 and 5.4.

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2.4.3 Additional Protective Devices
The Aurora inverter 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 UL 1741 standard). For
more detail see paragraph 8.6.
•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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3INSTALLATION
WARNING: The electrical installation of the Aurora inverter must be
performed in accordance with the electrical standards prescribed by the local
regulations and by the National Electric Code (ANSI/NFPA 70 standard).
WARNING: The connection of an Aurora inverter 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 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, transportation damage to the 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
other 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 in the event that the carrier sends an inspector to verify
damage!
•If the inspection reveals damage to the inverter, contact 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 Aurora inverter's original shipping package in the event that you should
ever need to return the inverter for repair.

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3.1.1 Inspecting package contents
Description Quantity (No.)
Aurora Inverter 1
Bag containing:
Nr.4 6.3x70 screws, nr.4 SX10 wall plugs, red cable
AWG10, black cable AWG10, Torx20 wrench, nr.1
6x10 screw, nr.1 d.18 washer,
1
Installation and Operator's Manual 1
Certificate of warranty 1
CD-ROM with communication software 1
3.2 Selecting the installation location
Installation location should be selected based on the following considerations:
•Height from ground level should be such as to ensure that the display and status
LEDs are easy to read.
•Select a well-ventilated location sheltered from direct sun radiation. Choose a
location that allows unobstructed airflow around the inverter.
•Allow sufficient room around the inverter to enable easy installation and removal
from the mounting surface.
•A door is provided on the front of the inverter to allow for hardware maintenance;
and the USB port for software connection is on right side wall of the inverter
(protected by a cover). Ensure free access to the right side; otherwise you will
have to remove the inverter from its mounting surface.
The following figure shows the recommended minimum clearances around the
inverter:

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Fig. 5 - Installation Location - Minimum Clearances around the Aurora Inverter