Power One AURORA Operating instructions

AURORA
Photovoltaic Inverters
INSTALLATION AND OPERATOR
MANUAL
Model number: PVI-3.8/4.6-I-OUTD-US Rev. 1.1


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TABLE OF CHANGES
Document
Revision
Author Date Change Description
1.0 Federico Mastronardi 03/08/10 First draft
1.1 Federico Mastronardi 09/12/10 First revision
KEEP THESE INSTRUCTIONS!
IMPORTANT SAFETY INSTRUCTIONS
POWER-ONE: Complete or partial reproduction of this document by any means
whatsoever is strictly forbidden without prior authorization of
Power-One.

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INSTRUCTIONS FOR READING THE MANUAL
This manual contains important instructions for safety and operation which must be
understood and carefully followed during 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 the manual
to highlight potential safety risks or useful information. The symbols are the
following:
WARNING: Paragraphs marked with this symbol contain actions and
instructions which must be fully understood and followed in order to avoid
potential harm to persons.
NOTE: Paragraphs marked with this symbol contain actions and instructions
which must be fully understood and followed in order to avoid damage to the
equipment and faults.
The equipment has various labels; those with a yellow background regard the safety
devices provided.
Make sure that you have read and fully understood the labels before installing the
equipment.
The symbols used are the following:
System earth 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 REGULATIONS
FOREWORD
AURORA must be installed in compliance with national and local laws.
AURORA has no user-serviceable parts.
Please contact the nearest authorized repair centre for all maintenance and repairs.
Please contact the retailer to find out the nearest assistance point.
We strongly recommend you read all instructions in this manual and notice the
symbols of the single paragraphs before installing or using the equipment.
The system must be connected to the distribution network only by qualified
personnel and only after the Body appointed to distribute electricity has given its
approval, as required by the national regulations in force.
The entire solar panel must be covered with dark opaque sheets before being
connected to the equipment. This is because its connection cables to AURORA
could have high voltage and generate serious hazard conditions.
NOTE: All the pictures present in this manual are only for clarification. The
final model may differ in some aspects from these pictures.
FCC REMARKS
These devices comply with Part 15 of the FCC rules. Operation is subject to following
two conditions: (1) these devices may not cause harmful interference, and (2) these
devices must accept any interference received, including interference that may cause
undesired operation.

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GENERAL
During inverter operation, parts may be powered, may lose proper insulation and may
move or rotate. In addition, some surfaces may become hot.
Unauthorized removal of necessary protections, improper use, faulty installation and
incorrect operation may lead to serious injury to people and/or equipment damage.
All operations regarding transport, installation and switching on, including
maintenance, must be carried out by qualified, trained personnel (in compliance
with all national provisions on accident prevention!!!).
Basic safety rules require using qualified and trained personnel that possess the skills
for assembly, mounting, start-up and operation of the product and the necessary
requirements for their trade.
ASSEMBLY
Devices should be assembled and cooled according to the specifications shown 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
When working with the inverter powered on, the current national regulations for the
prevention of accidents must be observed.
Electrical connections (e.g. conductor sections, fuses, PE connection, etc.) must
always be made in accordance with applicable regulations.

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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. Calibration changes are permitted by means of the operating software. Anytime
that the inverter has been disconnected from the power network, powered parts and
electrical connections should not be touched as some capacitors could still be charged.
Consequently, comply with all corresponding marks and symbols present on each
device. Ensure that all covers and doors are closed during operation.
MAINTENANCE AND SERVICE
The manufacturer's documentation must be complied with.
FIGURES AND IMAGES ON THIS MANUAL
Some of the images on this manual are from prototypes and only as example. The real
unit may differ in some particular from images.
KEEP ALL DOCUMENTS IN A SAFE PLACE!

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PVI-3.8-I-OUTD-S-US-PG
PVI-3.8-I-OUTD-S-US-NG
PVI-3.8-I-OUTD-US-PG
PVI-3.8-I-OUTD-US-NG
PVI-4.6-I-OUTD-S-US-PG
PVI-4.6-I-OUTD-S-US-NG
PVI-4.6-I-OUTD-US-PG
PVI-4.6-I-OUTD-US-NG
This document applies only to the inverter versions shown above.
Product name plate (PVI-4.6-I-OUTD-S-US-NG)
The name plate affixed to the inverter provides the following information:
1) Manufacturer code
2) Model code
3) Serial number
4) Week/Year of production

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TABLE OF CONTENTS:
1INTRODUCTION.......................................................................11
1.1 PHOTOVOLTAIC ENERGY...................................................................11
2DESCRIPTION OF THE SYSTEM..........................................12
2.1 F UNDAMENTAL E LEMENTS OF A P HOTOVOLTAIC S YSTEM : 'STRINGS' AND
'ARRAYS'...............................................................................................................16
2.2 D ATA T RANSMISSION AND C HECK ............................................................18
2.3 T ECHNICAL D ESCRIPTION OF AURORA ...................................................18
2.4 P ROTECTIVE D EVICES ................................................................................19
2.4.1 Anti-Islanding ...........................................................................................19
2.4.2 Grounding/differential Protection Fault...................................................20
2.4.3 Additional Protective Devices...................................................................20
3INSTALLATION ........................................................................21
3.1 P ACKAGE I NSPECTION ...............................................................................21
3.1.1 Inspecting package contents.....................................................................22
3.2 S ELECTING THE INSTALLATION LOCATION .................................................22
3.2.1 Wall mounting for -S-US models ..............................................................25
3.2.2 Wall mounting for -US models..................................................................27
3.3 B EFORE P ERFORMING THE E LECTRICAL C ONNECTIONS ............................29
3.3.1 ELECTRICAL CONNECTING and/or DISCONNECTING procedure (only
-S-US-xx models)................................................................................................30
3.3.2 ELECTRICAL CONNECTING and/or DISCONNECTING procedure (only
-US-xx models)...................................................................................................32
3.3.3 Removing the Front Cover and Accessing the Internal Terminal Block...34
3.3.4 Aurora Switch Box Description ................................................................35
3.3.4.1 AC and DC wire selection.........................................38
3.3.5 AURORA Inverter Typical Electrical Installations...................................39
3.3.5.1 Installation of -S-US-xx models................................39
3.3.5.2 Installation of -US-xx models ...................................40
3.3.6 Possible Aurora DC Input Configuration.................................................40
3.3.6.1 Independent Connection of the Aurora DC inputs....41
3.3.6.2 Parallel Connection of the Aurora DC inputs............42
3.3.7 Connection to the AC GRID .....................................................................43
3.3.7.1 Connection to the AC GRID for -S-US-xx models...44
3.3.7.2 Connection to the AC GRID for -US-xx models ......46

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3.3.8 Connection of RS485 and Alarm contact (optional) .................................47
3.3.8.1 Connection of the RS485 and Alarm contact for -S-
US-xx models ............................................................................47
3.3.8.2 Connection of the RS485 and Alarm contact for -US-
xx models...................................................................................48
3.3.9 Selction of the grid standard.....................................................................48
3.3.10 Ground Fuse replacement ...............................................................49
3.4 D ISCONNECTING THE AURORA I NVERTER FROM THE DC S WITCH B OX
( ONLY -S-US- XX MODELS ).......................................................................................50
3.4.1 ELECTRICAL DISCONNECTION OF THE INVERTER FROM THE
SWITCH BOX PROCEDURE.............................................................................50
3.5 CR2032 L ITHIUM B ATTERY R EPLACEMENT ..............................................51
4STARTING UP AND SWITCHING THE INVERTER OFF.53
4.1 S TART -U P P ROCEDURE ..............................................................................53
4.2 S TART -U P USING SIDE BUTTON ..................................................................54
4.3 S HUT -D OWN P ROCEDURE ..........................................................................55
5USER INTERFACE, MONITORING AND DATA
TRANSMISSION ................................................................................56
5.1 U SER I NTERFACE M ODE .............................................................................56
D ATA T YPES A VAILABLE .........................................................................................58
5.1.1 Real-Time Operational Data.....................................................................58
5.1.2 Internally Logged Data.............................................................................59
5.2 LED I NDICATORS .......................................................................................60
5.3 M ESSAGES AND E RROR C ODES ..................................................................65
5.4 LCD D ISPLAY ............................................................................................68
5.4.1 Connection of the System to the Grid........................................................68
5.4.2 Error Messages.........................................................................................69
5.4.3 First Phase - Electric Parameter Check ...................................................70
5.4.4 Main Menu................................................................................................73
5.4.5 Statistics ....................................................................................................74
5.4.5.1 Lifetime......................................................................74
5.4.5.2 Partial.........................................................................75
5.4.5.3 Today.........................................................................75
5.4.5.4 Last 7 days.................................................................76
5.4.5.5 Last Month.................................................................76
5.4.5.6 Last 30 Days..............................................................76

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5.4.5.7 Last 365 Days............................................................77
5.4.5.8 User Period................................................................77
5.4.6 Settings......................................................................................................78
5.4.6.1 Address......................................................................79
5.4.6.2 Display Set.................................................................79
5.4.6.3 Service.......................................................................80
5.4.6.4 New Password...........................................................80
5.4.6.5 Cash...........................................................................80
5.4.6.6 Time...........................................................................81
5.4.6.7 Language ...................................................................81
5.4.6.8 START-UP Voltage ..................................................81
5.4.6.9 Alarm.........................................................................81
5.4.6.10 Remote Control .....................................................82
5.4.6.11 UV Prot.time..........................................................83
5.4.6.12 MPPT.....................................................................83
5.4.6.13 Alarm Message......................................................84
5.4.7 Info............................................................................................................86
6DATA CHECK AND COMMUNICATION.............................87
6.1 C ONNECTION THROUGH RS-485 S ERIAL P ORT OR RJ12 C ONNECTORS .....87
6.1.1 RS-485 Serial Port....................................................................................87
6.1.2 RJ12 Connectors.......................................................................................88
6.2 M EASUREMENT A CCURACY ......................................................................91
7TROUBLESHOOTING..............................................................93
8TECHNICAL CHARACTERISTICS.......................................95
8.1 I NPUT V ALUES ...........................................................................................95
8.2 O UTPUT VALUES ........................................................................................99
8.3 G RID P ROTECTION C HARACTERISTICS .....................................................100
8.4 G ENERAL C HARACTERISTICS ...................................................................100
8.5 P OWER D ERATING ...................................................................................102

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1INTRODUCTION
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
In the process of energy conversion, for many years, industrial companies (major
energy consumers) have been experimenting with forms of energy saving and lower
emission of pollutants, through a prudent and rational use of known resources and the
research of new forms of clean and inexhaustible energy.
Renewable energy sources provide a major contribution to solving the problem. In this
field, the exploitation of solar energy to generate electricity (photovoltaic) is becoming
increasingly important worldwide.
Photovoltaic energy is an enormous advantage in terms of environmental protection
because the solar radiation we receive from the sun is directly converted into
electricity without any combustion process and without the production of nature-
polluting waste.

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2DESCRIPTION OF THE SYSTEM
AURORA is an inverter with the capability to supply the grid with energy obtained
from photovoltaic panels.
The photovoltaic panels convert the energy irradiated by the sun into electricity of the
direct current 'DC' type (through a photovoltaic field, also called a PV generator);
however, to use the electricity, it must be transformed into the alternating current 'AC'
type. This conversion, known as DC-AC inversion, is achieved efficiently by
AURORA without the use of rotating elements but only with static electronic devices.
When used in parallel with the network, the alternating current output from the
inverter flows directly into the domestic or industrial distribution circuit, connected in
turn to the public distribution network.
The solar energy system can thus feed all the connected user electrical loads.
If the energy supply from the photovoltaic system is lower than the user's load
requirement, the quantity of energy necessary to guarantee normal functioning of the
connected appliances is taken from the public distribution network. However, when
the opposite occurs, i.e. an excess of energy is produced, it is directly sent into the
public network, thus becoming available to other users.
In compliance with local and national regulations, the energy produced can be sold to
the distribution network or credited against future consumption, thus producing energy
savings.
Available Versions
PVI-3.8-I-OUTD-S-US-PG
PVI-3.8-I-OUTD-S-US-NG
PVI-3.8-I-OUTD-US-PG
PVI-3.8-I-OUTD-US-NG
PVI-4.6-I-OUTD-S-US-PG
PVI-4.6-I-OUTD-S-US-NG
PVI-4.6-I-OUTD-US-PG
PVI-4.6-I-OUTD-US-NG

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The S-US-xx models are provided with an integrated 600V, 25A DC switch.
Fig. 1a - Block diagram of version with integrated DC switch –PG

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Fig. 1b - Block diagram of version with integrated DC switch -NG

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The -US-xx models are supplied without a switch box and therefore without a 600V
integrated switch.
The -PG models are supplied with positive input grounded fig.1a (to be used only in
parallel mode).
The -NG models are supplied with negative input grounded fig.1b.
WARNING: The electrical schematics in Fig. 13 shows -NG models. In that
case the switch will physically disconnect only the positive DC inputs while
the negative are always grounded by the fuse. For -PG models the switch will
physically disconnect only the negative DC inputs while the positive are
always grounded by fuse.

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2.1 Fundamental Elements of a Photovoltaic System: 'STRINGS' and
'ARRAYS'
In order to significantly reduce installation costs of the photovoltaic system, especially
related to the wiring problem on the inverter DC side and the subsequent distribution
on the AC side, the STRING technology was developed.
A photovoltaic panel is composed of a great number of photovoltaic cells fixed onto a
single supporting base. A STRING is made up of a certain number of panels connected
in series. An ARRAY is one or more strings connected in parallel.
Large photovoltaic systems can be composed of several arrays, connected to one or
more AURORA inverters.
Maximizing the number of panels in each string, the cost and complexity of the
connection systems of the plant may be reduced.
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 520 Vdc for any reason. Because of the negative thermal coefficient
of the photovoltaic modules' open circuit voltage, maximum voltage is
obtained in conditions of minimum environmental temperature. It is
recommended to check the photovoltaic generator's configuration with the
Aurora Designer dimensioning software.
NOTE: A minimum Vstart input voltage of 200 Vdc ( the voltage can be set
from the control panel in a range between 120 Vdc and 350 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
Vdc input voltage value in a range between 70% of the value set by Vstart
and 520V to the grid (see Fig. 31 and Fig. 32 Fig. 1 for clarification).
The current of each array must also be within the inverter's limits. For AURORA the
maximum current from each input can be 14 Adc for PVI-4.6-I-OUTD, 12.5 A for
PVI-3.8-I-OUTD.
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
distribution network on the AC side.
Every AURORA inverter works independently of the others and feeds power into the
grid with the maximum power available from its own section of photovoltaic panels.
Decisions on how to structure a photovoltaic system depend on a number of factors
and considerations, such as the type of panels, the available space, the future location
of the system, long-term energy production targets, etc. A configuration program
(Aurora Designer) which can aid correct dimensioning of a photovoltaic system is
available on the Power-One website (www.power-one.com).

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Fig. 3 - Simplified diagram of a photovoltaic system
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. An
optional Aurora Easy-Control system is also available for remote monitoring via the
Internet, analog modem. Moreover, with another option, a radio monitoring system
can be used (PVI-Desktop + PVI-Radiomodule) to obtain a remote display terminal
connected wireless.
2.3 Technical Description of AURORA
Fig. 1 shows the block diagram for AURORA. The main blocks 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.
These versions of AURORA have a high frequency transformer, i.e. with galvanic
insulation between input and output. The high frequency transformer allows the
primary (DC side) to have galvanic isolation from the secondary (AC side)
maintaining very high performance in terms of energy yield and export. AURORA is
equipped with the necessary protective devices to ensure safe operation in compliance
with applicable regulations as described in the paragraph on protective devices.
DC disconnecting
switch
AC
disconnecting
switch

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The block diagram shows an AURORA PVI-3.8/4.6-I-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 with different positions and facing different directions.
Each array is controlled by an MPPT control circuit.
Thanks to AURORA’s high efficiency and large heat dissipation system, this inverter
provides operation at maximum power in a broad range of ambient temperatures.
The inverter is controlled by two independent Digital Signal Processors (DSP) and one
central microprocessor.
This way, network 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
perform data processing.
This guarantees optimal performance levels of the whole complex and high yield in all
insulation and load conditions, always in full respect of directives, laws and
provisions.
2.4 Protective Devices
2.4.1 Anti-Islanding
When the local distribution network 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
network, all in full compliance with the applicable national standards and laws. To
avoid possible islanding operations, AURORA is provided with an automatic
disconnection protection system called 'Anti-Islanding'.
The AURORA PVI-3.8/4.6-I-OUTD 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

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2.4.2 Grounding/differential Protection Fault
WARNING: Some national and local regulations make it compulsory for
one of the DC input terminals to be connected to the system's earth. Carefully
evaluate the national standard so that the inverter's input is correctly
grounded.
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 ground conductors.
For further details on the grounding of the terminals and protective devices, please
refer to section 3.3.10.
NOTE: For further details of AURORA shutdown or possible causes of
malfunction, please refer to paragraphs 5.3.
The protective devices for ground failures comply with these standards:
CSA-C22.2 N.107.1-01 UL Std N.1741
2.4.3 Additional Protective Devices
AURORA is equipped with additional protections to guarantee the safe operation
under any circumstances. Such 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);
Automatic power limitation control based on internal temperature monitoring to
avoid overheating (heat sink temperature ≤158°F).
AURORA’s many control and protection devices result in a redundant structure
to guarantee operation in absolute safety.