Sofar HYD3000-ES User manual

HYD 3000/4000/5000/6000-ES
User Manual
2018-8-8
Version V1.00 (for firmware V1.00)

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CONTENT
1. HYD-ES inverter Introduction...................................................................................................................................4
2. Safety Notes.............................................................................................................................................................5
2.1. Safety Notes.................................................................................................................................................5
2.2. Installation and Maintenance Notes............................................................................................................5
2.3. Signs on the inverter....................................................................................................................................6
3. Installation...............................................................................................................................................................8
3.1. Product Overview........................................................................................................................................8
3.2. Packing List ..................................................................................................................................................9
3.3. Installation Environment .............................................................................................................................9
3.4. Installation Tools........................................................................................................................................10
3.5. Installation Position ...................................................................................................................................11
3.6. Mount HYD-ES inverter..............................................................................................................................11
4. Electrical Connection.............................................................................................................................................13
4.1. Battery Connection....................................................................................................................................14
4.2. PV Connection ...........................................................................................................................................14
4.3. CT / CAN / RS485 / NTC connection ..........................................................................................................16
4.4. Grid Connection.........................................................................................................................................18
4.5. Critical Load Connection (EPS function) ....................................................................................................19
5. Buttons and indicator lights...................................................................................................................................20
5.1. Buttons: .....................................................................................................................................................20
5.2. Indicator lights and status of HYD-ES inverter...........................................................................................20
6. Operation...............................................................................................................................................................21
6.1. Double Check.............................................................................................................................................21
6.2. First Time Setup (IMPORTANT!).................................................................................................................21
6.3. Commissioning ..........................................................................................................................................24
6.4. Menu .........................................................................................................................................................25
6.4.1. Basic setting:..................................................................................................................................26
6.4.2. Advanced setting: ..........................................................................................................................33

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6.4.3. Event List........................................................................................................................................36
6.4.4. System information interface ........................................................................................................37
6.4.5. Energy Statistic：...........................................................................................................................38
6.4.6. Software upgrade ..........................................................................................................................39
7. Technical Data........................................................................................................................................................40
8. Troubleshooting.....................................................................................................................................................42

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1. HYD-ES inverter Introduction
The HYD-ES hybrid inverter is used in PV system with battery storage.
Energy produced by the PV system will be optimized for maximum self-consumption.
The HYD-ES inverter can work in auto or time-of-use (TOU) mode, charge / discharge the battery when needed. In
auto mode, the HYD-ES inverter will charge surplus PV energy into the battery & discharge battery to supply power to
local load when PV energy is not enough.
In case of blackout, HYD-ES inverter can work in Emergency Power Supply (EPS) mode. HYD-ES inverter will utilize
power from PV panels & energy stored in the battery to supply power to critical load.
Fig. 1 HYD-ES inverter schematic diagram

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2. Safety Notes
Before installation, please make sure you read & understand this manual. The HYD-ES inverter strictly comply with
safety rules of design and testing. During the installation, operation and maintenance, operators should abide by local
safety regulations. Improper operation may cause an electric shock or damage the equipment and properties.
2.1. Safety Notes
Electrical installation and maintenance must be carried out by competent electricians according to local
regulations.
HYD-ES inverter can only be installed by qualified electrician, and only those who have appropriate accreditation,
as required by local authority.
Do NOT put explosives or flammable materials, e.g. gasoline, kerosene, diesel, oil, wood slab, cotton, or rag close
to batteries or HYD-ES inverter.
Disconnect AC connection first, then disconnect battery & PV(PV1&PV2), then wait at least 5 minutes (discharge
capacitors) before maintenance to prevent electric shock.
HYD-ES inverter shall be disconnected completely (BAT, PV & AC) while being maintained.
HYD-ES inverter can be very hot during working. Switch off HYD-ES inverter & wait HYD-ES inverter to cool down
before maintenance.
Keep children away from batteries & HYD-ES inverter.
It’s NOT allowed to open the front cover of HYD-ES inverter. This will void the product warranty.
HYD-ES inverter damaged by improper installation/operation is NOT covered by the product warranty.
2.2. Installation and Maintenance Notes
The battery has been charged more than 60% before being delivered and shall be prevented from short circuit
during transportation and installation.
HYD-ES inverter/batteries shall be placed in a well-ventilated place. Do not put the HYD-ES inverter/batteries in
an airtight or badly ventilated place or cabinet. This can be very harmful to system performance & service life.
Keep HYD-ES inverter/batteries away from direct sunshine. Don’t put HYD-ES inverter/batteries close to a furnace
or fire. The can lead battery to leak even explode.
The current capacity of DC power cables (from battery to inverter) should be at least 90A. Use short DC power
cables to avoid high voltage drop & power loss.
Use a multimeter to check the batter voltage & polarity before switching ON batteries. Make sure connections
are correct according to this manual.
Use a multimeter to check the PV voltage & polarity before switching ON PV isolator. Make sure connections are
correct according to this manual.
If you want to store the batteries without using them, they should be disconnected from HYD-ES inverter, and be
kept in a cool, dry, and ventilated environment.

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Battery maintenance operators shall have the knowledge and technical skill for battery maintenance;
All batteries connected in parallel should be of the same model and have same firmware version. This is a design
issue needs to be considered by designer/installer, particularly when replacing batteries or modifying an existing
energy storage system.
HYD-ES inverter is transformer-less, therefore the positive pole and negative pole of the PV array are NOT
grounded. Otherwise it will cause inverter failure. In the PV system, all non-current carrying metal parts (such as:
PV module frame, PV rack, combiner box enclosure, inverter enclosure) should be connected to earth.
Warning: Do not disassemble or break the battery. Its electrolyte can be toxic and damage your skin and eyes.
Warning: follow the following rules during battery installation/maintenance.
a) Take off your watch, ring, and other metal objects.
b) Only use tools with insulated handles.
c) Wear rubber gloves and shoes.
d) Do not put tools or metals above the battery.
e) Switch off HYD-ES inverter & batteries before connecting / disconnecting battery terminals.
f) Battery positive/negative poles should be isolated from ground.
2.3. Signs on the inverter
There are some symbols which are related to security on the inverter. Please read and understand the content of the
symbols before system installation.
This symbol indicates a hazardous situation which could result in injuries, if not avoided.
Risk of Electric Shock and wait at least 5 mins after switching OFF HYD-ES inverter.
Be careful of high voltage and electric shock.
Be careful of hot surface.
Comply with the Conformity Europeanness (CE) certification.
Earth terminal.

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Please read this manual before installing ZCS HYD-ES inverter.
This indicates the degree of protection of the equipment according to IEC standard 70-1
(EN 60529 June 1997).
Positive pole and negative pole of the DC voltage (PV & Battery).
This side up, HYD-ES inverter must always be transported, handled and stored in such a
way that the arrows always point upwards.

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3. Installation
3.1. Product Overview
HYD-ES inverter is 100% strictly inspected before package and delivery. It is forbidden to put the HYD-ES inverter
upside down during delivery.
CAUTION
Please check the product package and fittings carefully before installation.
Fig. 2 HYD-ES inverter overview
1
DC switch
6
Current transformer port
2
Battery input terminals
7
Load connection port
3
PV input terminals
8
Grid connection port
4
Wi-Fi/GPRS stick
9
LCD
5
BMS communication port
10
breather valve

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3.2. Packing List
Inspect the package and fittings carefully before installation. You should have the following fittings:
Mounting Bracket × 1
AC terminal × 6
M5 screw × 2
Battery terminal × 2
M6 flat washer × 8
Expansion Bolts × 8
Terminal cap × 4
CT terminal × 2
Current Transformer × 1
User Manual × 1
Warranty card × 1
Quality Certificate × 1
Communication cable × 1
PV+ input terminal×2
PV- input terminal×2
NTC×1 (Long-3M)
Fig. 3 Accessories of HYD-ES inverter
3.3. Installation Environment
Choose a dry, clean, and tidy place, convenient for installation
Ambient temperature range: -25℃ ~ 60℃
Relative humidity: 0 ~ 100% (non-condensed)
HYD-ES inverter shall be installed in a well-ventilated place
No flammable or explosive materials close to HYD-ES inverter
The AC overvoltage category of HYD-ES inverter is category III
Maximum altitude: 2000m

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3.4. Installation Tools
The following tools shall be prepared before installation:
No.
Tool
Model
Function
1
Hammer drill
Recommend drill dia.6mm
Used to drill holes on the wall
2
Screwdriver
wiring
3
Wire stripper
Strip wire
4
4mm Allen Key
Turn the screw to connect rear panel
with inverter
5
Crimping tools
Used to crimp power cables
6
Multi-meter
Used to check grounding
7
Marker pen
Used to mark signs
8
Measuring tape
Used to measure distances
9
Level
Used to ensure that the rear panel is
properly installed
10
ESD gloves
Operators wear
11
Safety goggles
Operators wear
12
Anti-dust respirator
Operators wear

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3.5. Installation Position
HYD-ES inverter should be vertically mounted (to ensure fast heat dissipation), please choose a position without direct
sunlight / snow accumulation to install HYD-ES inverter. Please the installation position is well-ventilated.
OK
NO
Fig. 4 Installation Position of HYD-ES inverter
3.6. Mount HYD-ES inverter
Step 1: Put the mounting bracket properly on the wall, mark these 8 drill holes using a marker pen. Drill 8 holes (drill
bit 6mm) on the wall.
Step 2: Insert the expansion screw vertically into the hole, note the insertion depth. (not too shallow or too deep)
Step 3: Fix the mounting bracket on the wall using bolts & flat washers.

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Step 4: Put HYD-ES inverter on the mounting bracket.
Step 5: Earth HYD-ES inverter using the grounding hole on the heat sink.
Step 6: OPTIONAL: you can lock HYD-ES inverter to the mounting bracket.
Step 5 Step 6

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4. Electrical Connection
CAUTION
High voltages in power conversion circuits. Lethal hazard of electric shock or serious burns.
All work on the PV modules, inverters, and battery systems must be carried out by qualified
personnel only.
Wear rubber gloves and protective clothing (protective glasses and boots) when working on high
voltage/high current systems such as INVERTER and battery systems.
CAUTION
HYD-ES inverter is intended to be used in PV system with battery storage. If not used as intended,
the protection provided by the equipment may be impaired.
Fig. 5 Electrical connections

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4.1. Battery Connection
Fig. 6 Battery connection (Measure battery wires polarity/voltage before connection)
Step 1: Loosen 4 screws (A) using a screwdriver (Fig. 6);
Step 2: Remove the waterproof cover (B), loosen the cable gland (C), and then remove the stopper (G);
Step 3: Route the battery wires (F) through the cable gland, then connect battery wires using OT terminal (E);
Step 4: Fasten the waterproof cover using 4 screws.
4.2. PV Connection
Recommended DC input cable specifications
Cross-Sectional Area (mm2)
External Cable Diameter(mm2)
Range
Recommended Value
4.0~6.0
4.0
4.5~7.8
Procedure:
Step 1 Prepare PV positive and negative power cables
1. Positive metal contact 2. Negative metal contact
Fig. 7 prepare PV positive and negative power cables

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Step 2 Insert crimped PV positive and negative power cables into corresponding PV connectors
3. Positive connector 4. Negative connector
Fig. 8 prepare PV positive and negative connectors
Step 3 Make sure the DC voltage of each PV string is less than 600V DC and polarities of PV power cables are correct.
Insert the positive and negative connectors into HYD-ES inverter until you hear a "click" sound, as shown in Fig. 9.
1. Bayonet
Fig. 9 Connect PV connectors
CAUTION
Before removing the PV positive and negative connectors, ensure that the DC
SWITCH is OFF.
Follow-up Procedure
Use a MC4 wrench to disconnect PV connectors, as shown in Fig. 10.
Fig. 10 Disconnect PV connectors

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4.3. CT / CAN / RS485 / NTC connection
CT (Current transformer) can measure the value and direction of AC current. Refer to Fig. 11 for the correct connection
of CTa.
Fig. 11 CTa connection
Step 1: Refer to Fig. 11 for correct position of CTa. Wrap the CT around L wire of incoming mains, make sure that the
CT arrow direction is “home → grid”.
Step 2: You can use network cable & terminal caps to extend CT wires if necessary, the maximum CT cable length is
200m.
CT wire
Extension cable (network cable)
HYD-ES inverter
Red
Orange / white orange / brown / white brown
CT+
Black
Green / white green / blue / white blue
CT-

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Fig. 12 CT / CAN / RS485 / NTC connection
Step 3: Loosen 4 screws (part A) using a screwdriver (Fig. 12)
Step 4: Remove the waterproof cover (part B), loosen the cable gland (part C), then remove the stopper (part G)
Step 5: Route CT cable through the cable gland, connect CT cable to CT terminal, then insert CT terminal into
corresponding ports.
Step 6: One communication cable (between battery BMS & HYD-ES inverter) is provided in the HYD-ES inverter
accessory bag. One inverter end, one BAT end.
Route the communication cable (inverter end) through the cable gland, insert the 4P4C connector to
HYD3000/4000/5000/6000-ES CAN port. Insert the 8P8C connector (BAT end) to PYLONTECH battery CAN port.
Communication cable between battery & HYD-ES inverter
CAN communication
HYD-ES inverter
CAN port
CANH---pin1 CANL---pin2
RS485 port
485A----pin3 485B----pin4
PYLONTECH US2000 PLUS / US2000B
CAN Port
CANH---pin4 CANL---pin5
RS485 port
485A----pin1 & pin8
485B----pin2 & pin7
Step 7: Connect NTC for lead acid batteries only:

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Fig. 13 NTC connection
Step 8: fasten the waterproof cover using 4 screws.
4.4. Grid Connection
Step 1: Loosen 4 screws (part A) using a screwdriver (fig. 11)
Step 2: Remove the waterproof cover (part B), loosen the cable gland (part C), then remove the stopper (part G)
Step 3: Route a 3-core cable through GRID cable gland, then connect 3 wires to corresponding terminal blocks.
(BROWN – L, BLUE – N, YELLOW/GREEN – PE)
Step 4: Fasten the waterproof cover using 4 screws.
Fig. 14 Grid & Load connection

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4.5. Critical Load Connection (EPS function)
Critical load: in case of grid outage, if EPS function is enabled, HYD-ES inverter will work in EPS (Emergency Power
Supply) mode, utilize the PV power & energy stored in the battery to supply power to critical load via LOAD connection
port.
LOAD connection port is only for critical load connection. The power of critical loads must be less than 3000VA.
The connection procedure of LOAD port is the same as grid connection (Fig. 14).
Change-over positions
CAUTION
The changeover switch is necessary.
While checking/repairing critical load, make sure change-over switch is at position 0.
While checking/repairing HYD-ES inverter, make sure change-over switch is at
position 0 & HYD-ES inverter is disconnected from grid.
Under normal conditions: change-over switch is at position 1. HYD-ES inverter can supply power to critical load
in case of blackout.
If the HYD-ES inverter is faulty, manually change the switch to position 2. Grid will supply power to critical load.
Fig. 15 Change-over Switch connections

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5. Buttons and indicator lights
On-Grid Status Light
Off-Grid Status Light
Alarm Light
Back Up Down OK
Fig 16. Buttons and indicator lights
5.1. Buttons:
press “Back” to the previous screen or enter the main interface;
press “Up” to the upper menu option or value plus 1;
press “Down” to the lower menu option or value minus 1;
Press “OK” to select the current menu option or switch to the next digit.
5.2. Indicator lights and status of HYD-ES inverter
Status of HYD inverter
On Grid
Green light
Off-Grid
Green light
Alarm
Red light
On-grid
ON
Standby (On-Grid)
Flashing
Off-Grid
ON
Standby (Off-Grid)
Flashing
Alarm
ON