Power One AURORA User manual

AuroraUniversalInstallationGuide
Power‐OneAuroraInverters
This installation document covers all details for installing the Aurora Universal System hardware
to
work directly with the Power-One Aurora inverter(s) . The Fat Spaniel Technologies (FST)
Management System within the Aurora Universal System collects and analyzes energy generation
and usage data for your Aurora inverter(s). Once the hardware is installed, you will need to login to
the FST Partner Portal website to verify the internet is connected properly and verify that the data in
being received.
1

AuroraUniversalInstallationOverview
Power Supply and
Meter Assembly
Data Logger
DIN Rail
DB9 Adapter
LAN Ports
Select Location and Mount the Aurora Universal Enclosure
Make Power and Instrument Connections to the DIN Rail
Make Connections to Devices to be Monitored and the Internet
Verify and Validate the Installation via the Internet
1
RS485 Connections
Data Logger Power
Power Connector Block CT Connector Block
Power Connector Block
Installation Steps
4
3
2
2

EquipmentandSupplies
Wesupply:Yousupply:
AuroraUniversalSystem,whichincludes:
FatSpanielDataLoggerwithDB9adaptercard(s)
PowerSupply/MeterAssembly(Meteroptional)
DINRailConnectorBlock
Accountname/Passwordforaccesstoinverterdata
Power‐OneAuroraInverter(s)
MountingHardware,includingcabletiesandconduit
120Vwalloutletor120/230/208/240Vaccircuitpower
RS45Signalcablefrominvertertodatalogger
Straight‐throughCAT‐5NetworkcabletoLANportor
aCellularRouter
SiteSelectionandMounting
SiteLocationPlanning
Site selection depends on how many inverters you are connecting to the Aurora Universal and if
other devices are being connected to the system. For multiple inverters, inverters are “daisy-chained”
together using twisted pair signal cable with the first inverter in the chain connected to the Aurora
Universal. The Aurora Universal is connected to the internet using CAT-5 or CAT-5 compatible
cabling.
For sites with multiple inverters or long distances between interconnections, if may be useful to draw
a map of site installation, so you are sure the selected site is appropriate.
The internet connection is only limited by the typical restraints and conditions that apply to any data
network, as long as the router connected to the Data Logger is reachable over a public network. The
internet connection point may be a router or switch that is connected to a public network. It may also
be a cellular router affixed within the Aurora Universal enclosure or a cellular router shared by
multiple Aurora Universal systems.
If connecting other inverters/device types to the Aurora Universal System such as an environmental
measurement system, these devices must be connected through the secondary DB9 adapter card.
CablingRequirements
Below are the rules regarding cable lengths:
• Maximum 100 m (300 ft) between Aurora Universal and the internet connection point (LAN)
• Maximum 1,000 m (3,000 ft) between Aurora Universal and the last inverter
• Maximum 1,000 m (3,000 ft) between Aurora Inverters
• Maximum 1200 m (4,000 ft) overall length of daisy-chained inverters
RS45 signal wiring between inverters is low-voltage wiring and should be shielded from electrical
interference, such as high voltage wires or fluorescent light ballasts.
3

For connection between the Data Logger and the internet, ordinary straight through CAT-5 cable
works for most applications. However, ordinary CAT-5 is low-voltage wiring and should be shielded
from electrical interference. If outdoor exposure or proximity to a noise source is a concern, Power-
One recommends:
• Belden 7919A or 9842
• General Cable Carol C0890
It may be necessary for your application to string CAT-5 wire through conduit. It may not be
possible to string the wire without cutting off and re-attaching one of the RJ45 connectors. The
wiring diagram for RJ45 connectors on CAT-5 cable is provided as a convenience if you are
required to re-attach an RJ45 connector.
Pin # Color
1 Orange/white
2 Orange
3 Green/white
4 Blue
5 Blue/white
6 Green
7 Brown/white
8 Brown
DeviceMounting
The exact method of mounting the Aurora Universal enclosure is left to the installer. Here are some
tips and best practices:
• Ambient temperature around the box should remain between –20oC and 60oC (this should be verified)
• If possible, install the enclosure where the enclosure is shaded from direct summer sunlight.
• Keep in mind that clearance between components in the enclosure and the enclosure wall is at least 2
inches, except on back wall of enclosure.
• Enclosure weighs between 5 and 10 lbs. Bracket mounts supporting up to 50 lbs are recommended.
• Enclosure must be mounted off the ground.
• Enclosure door swings out to the left. Make sure you leave enough room to open the enclosure.
• If mounting outside, drill holes for conduit through the bottom of the enclosure and use conduit or
glands to protect the integrity of the enclosure. Aurora Universal is a NEMA 3R rated enclosure. You
must use appropriate conduit fittings to preserve the NEMA rating and your warranty
.
• Wall-mounting or pole-mounting kits are available. (Do we sell these? Can we point them
somewhere?)
4

5
PreparingInvertersforConnectiontoAuroraUniversal
Inverters must be connected to each other in a daisy chain before being connected to Aurora
Universal. The RS-485 serial port uses a three-wire cable, two wires are for signals and a third one
for ground connection. RJ12 ports and appropriate cabling can serve as the connection between
inverters. (I assume it would be OK to use the RJ12 connectors between inverters and use RS485 to
Auurora Universal?)
1. Install the Power-One Aurora inverter(s) as per the inverter documentation for the
inverter model you are working with. Adhere to all cautions and safety instructions in
the Power-One Aurora Inverter manual and the proper tools to remove the access
panel .
2. Verify the first (or only) inverter address. Make sure the first (or only) inverter
address is set to 2 (the default). For detailed information on configuring addresses,
refer to the section on “address selection” in the inverter installation manual. If you
have only one inverter, stop and proceed to the next section.
3. If more than one inverter is used, configure each additional inverter address,
incrementing by 1. For example, in the case of three inverters, the first address
would be 2, and the next two inverter addresses would be 3 and 4 . For detailed
information on configuring addresses, refer to the section on “ address selection ” in
the inverter installation manual .
CAUTION!
FSTusestheinverteraddresstotrackdataforeachinverterandtoestablishtheWebsiteview .
OncetheinverterisconnectedtotheFSTmonitoringequipmentandisreportingdatatothe
FSTserver,theaddressmay not bechangedwithoutincurringadditionalexpensetothe
customer . 
Iftheaddressmustbechangedatalatertimeoraninverterisreplaced,FSTTechnicalSupport
mustbecontacted
before  thechangeismade . 
Ifforsomereasontheinverterscannotbeconfiguredasspecified,FSTTechnicalSupportmust
be
contacted beforeserviceisstarted .

4. Connect all inverters in the chain (make a serial link between inverters). You need to
locate the RS-485 terminal block for each inverter in the chain. Inverters are
connected by twisted pair signal cable from one RS-485 terminal block in the inverter
to the next inverter in the chain. The RS-485 connectors may be a screw terminal
block or cage-clamp connector, and there may also be RJ12 ports depending on the
Aurora inverter. An example terminal block from an Aurora inverter is shown below.
For easier installation, the inverter typically features two holes so that input and
output cables can be separated when multiple units are connected in a daisy chain.
Cable is routed through the holes located at Inverter bottom that are blanked with
waterproof plugs. Power-One supplies cable glands that must be installed in the holes
to protect the inverter. After passing through the cable gland, cables are connected
inside of the unit to RS-485 terminal blocks. Terminal blocks are reached by
removing a door or covering over the RS-485 terminal block.
Some Aurora inverters allow connections between inverters using RJ12 connectors
and cabling. However, note that the connection between the first inverter in the chain
and the Aurora Universal must be made through the RS-485 connectors.
6

5. Terminate the last inverter. Make sure the last inverter is terminated as per the
Aurora inverterdocumentation. The DIP switch on the last inverter’s RS-485 terminal
block must be set to ON. See the figure in step 4 above for an example of the DIP
switch that needs to set to ON for the last inverter. For detailed information, refer to
the section on communications in the inverter installation manual.
7

ConnectthePowerSource
The Aurora Universal System comes without holes for electrical connections to the enclosure.
1. Drill a hole in the enclosure to string the power supply wire. The power connection
point in the Aurora Universal in at the lower left of the enclosure. This may also
require conduit to house the wire if required for your installation.
Recommended Area for Drilling Holes
Circuit Breaker
Power
Supply
Block
2. Make sure power is OFF to the power wires coming into the Aurora Universal
enclosure. Attach incoming power wire to the power connector on the DIN Rail of the
Aurora Universal (connectors farthest to the left).
3. Make sure the circuit breaker switch on the DIN Rail power connector block is OFF.
Connect the power supply wire to 120, 208, or 240VAC.
ConnectInstruments
If you have no meter in the Aurora Universal, skip this section. Instruments are attached to Aurora
Universal only if you have a revenue grade meter with your system (Aurora Revenue Grade). The
Aurora Universal System comes without holes for electrical connections to the enclosure.
1. Use the same hole/conduit drilled for the power source, or drill a second hole if
appropriate for your installation. The instrument connection points in the Aurora
Universal are at the lower portion of the enclosure. This may also require conduit to
house the wires if required for your installation.
8

2. Attach incoming Voltage wires to the CT sensing block on the DIN Rail of the
Aurora Universal (connectors in the middle of the DIN Rail).
Voltage Sensing Block CT Landing Block
3. Attach incoming CT wires to the CT landing block on the DIN Rail of the Aurora
Universal (connectors farthest to the right).
ConnectInverterandEthernet
The Aurora Universal System comes without holes for electrical connections to the enclosure.
The physical connection to Ethernet can be completed by stringing a CAT-5 or CAT-5 compatible
cable between the Data Logger and an Ethernet switch or router. Connecting the Data Logger to a
cellular router can also be used. If using a cellular router, it may be useful to attach the cellular
router to the inside right wall of the Aurora Universal enclosure.
1. Drill a separate hole in the enclosure for the low voltage wires. (Is this absolutely
required? If not, are there any restrictions other than “room” to putting wires in the
same conduit?) The connection points in the Aurora Universal are on the Data Logger
in the right side of the enclosure. This may require conduit to house the wires if
required for your installation.
2. Connect the RS-485 data cable from the Data Logger to the RS-485 terminal block in
the first Aurora inverter in the chain using the pin callouts in Table 1. Refer to the
diagram and table below to make the proper connections. Refer
to the Power-One
Aurora Inverter installation documentation for details on the RS - 485 terminal block
location . Make sure to use twisted pair wire to pins 2 and 3 on the Data Logger
Terminal Block.
9

AuroraInverter RS‐485
TerminalBlockConnection
DataLoggerTB25Terminal 
BlockConnection
RTN 4(white)
+TR 2(Red) 
‐TR 3(black)
RS485 Terminal
Connections
Data Logger
DB9 Adapter
To Network via Switch
or Router
+TR
-TR
RTN
First Inverter
3. If you do not have a cellular router, skip to step 4. If you have a cellular router,
connect the cellular router cable (RJ45) to the D port labeled LAN1 on top of the
Data Logger. If this is your permanent means of connecting to Ethernet, it is not
necessary to run the CAT-5 cable described in step 4. If the cellular router is being
used for a temporary connection for installation verification or diagnostics, run the
CAT-5 cable as described in step 4. Switch the Cellular router ON.
4. Run the CAT-5 or CAT-5 equivalent cable to an Ethernet access point, usually a
switch or router. Refer to Cabling Requirements if you need to need to cut and re-
attach an RJ45 connector. Connect the CAT-5 cable (RJ45) to the Data Logger port
labeled LAN1. Leave the cable temporarily disconnected if a cellular router is already
connected.
5. You now ready to test power and the physical connections. Either a cellular router,
LAN switch, or LAN router must be connected through the LAN1 port of the Data
Logger. Turn on the power to the Aurora Universal using the breaker on the DIN
Rail.
10

6. Check the power connection. You should see a green light on the power supply
indicating that the power supply is operating properly. If no light is present, check to
make sure the power to the power supply wires is ON, and check your wiring to the
power terminal block on the DIN Rail.
7. Check the Data Logger power. There are 4 LED lights on the front of the Data
Logger. The Ready LED should be ON.
8. Check the Data Logger Ethernet connection. Look at the top of the Data Logger; you
should see a green light above the LAN1 port.
9. There is a sticky label on the Data Logger with a MAC Address (for example,
45:23:AF:4C:5A:12). Write down the MAC Address (Will this now be a Logger
ID?) and provide it to the person performing system validation.
SystemValidation
System validation is performed over the internet through a computer logged into an account at the
Fat Spaniel website. The purpose of System Validation is to verify that communication links are
established, data from monitored equipment is being received, and the data is being reported
correctly.
Go to Fat Spaniel public web site and select the login page, http://www.fatspaniel.com/log-in/.and
Login to the Partner Portal with your account name and password. Select Quick Start Guide from
the Partner Portal home page for instructions on how to perform System Validation.
If you are familiar with Aurora Universal installation and Solar Plant Vision, go to
http://www.fatspaniel.com/log-in/ and log in to Solar Plant Vision with your account name and
password and verify that data is being received from the Data Logger.
Fat Spaniel also has on-site diagnostic tools to assist with validating the installation or debugging
installation/communication problems. Information about these tools can also be found on the Partner
Portal website.
11