SolarMax 10 005 981 User manual

Installation manual
SolarMax P series
I/O module

Sputnik Engineering AG
Länggasse 85
CH-2504 Biel/Bienne
Email: [e-mail]
© Sputnik Engineering AG 2014

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Contents
1 About this installation manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Where to keep this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Symbols on the I/O module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Description � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
3.1 Identication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
4.1 Storing the I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Installing the I/O module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.4.1 External shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.4.2 External power control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.4.3 SPI logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.4.4 Multi-function relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.4.5 Lightning protection monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.6 S0 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.4.7 Control of self-consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5 Conguration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22
5.1 Conguring the status signaling contact. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.1 Graphics display conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.2 Conguration with MaxTalk 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Conguring the lightning protection monitor. . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 Graphics display conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 Conguration with MaxTalk 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Control of self-consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Conguring the “Pac electric meter” operating mode . . . . . . . . . . 24
5.3.2 Conguring the "Pac inverter" operating mode . . . . . . . . . . . . . . . 25
6 Replacement� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
6.1 I/O module disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 I/O module disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Warranty � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28

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1 About this installation manual
1�1 Scope
This installation manual is valid for the I/O module, item no. 10005 981 and item no.
10 005 380 (accessory component for the SolarMax inverter 2000P, 3000P, 4000P,
4600P and 5000P).
1�2 Target groups
The I/O module may only be installed by qualied electricians (e.g. electrical contractors,
electrical plant installers, electromechanics, industrial electronic engineers).
1�3 Where to keep this manual
The plant operator must ensure that this installation manual is available to the relevant
persons at all times. If this original document is lost, an up-to-date version of this instal-
lation manual can be downloaded from our website at any time (www.solarmax.com).
1�4 Symbols used
The following safety instructions and general information are used within this instruction
manual.
DANGER!
Non-observance of these safety instructions may immediately cause serious
injuries or death.
WARNING!
Non-observance of these safety instructions may cause serious injuries.
CAUTION!
Non-observance of these safety instructions may cause minor or medium
injuries.
ATTENTION!
Non-observance of these safety instructions may cause material damage.
Note
Notes contain extended information or facilitate the operation of the inverter
and/or I/O module.

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2 Safety
2�1 Intended use
The I/O module is intended exclusively for extending the interface for SolarMax P series
inverters. Any other use is contrary to the design purpose.
2�2 Safety Instructions
DANGER!
Fatal electric shock hazard!
 Never open the inverter while it is in operation.
 Before you start installation work, ensure that all connectors and cables
are de-energized.
 Remove the cover and the contact protection on the inverter as described
in the instruction manual.
 Observe the safety instructions in the inverter instruction manual.
2�3 Symbols on the I/O module
Symbol Description
The I/O module can be damaged by electrostatic discharge (ESD). Take all neces-
sary measures to avoid ESD.

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3 Description
The I/O module offers extra functions and interfaces for monitoring and remote control of
the PV power plant. It is inserted into the slot provided in the inverter.
3�1 Identication
The I/O module can be identied by a sticker on the printed circuit board, see Figure 1/
Pos 1).
1
Figure 1 Identification
Item no� - I/O module Printed circuit board
10 005 380 BG10418
10 005 981 10 005 980

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3�2 Connections
The connection terminals of the I/O module are illustrated in Figure 2.
S0−
S0+
BS−
BS+
12
NC
14
11
K3
K4
K1
K2
NA
N
K5
K6
Figure 2 I/O module connections
Contact Description
S0+ S0 interface* (control of self-consumption)
S0−
BS+ Lightning protection monitor
BS−
N External shutdown / external power control / SPI frequency monitoring
NA External shutdown
NC not used
11 Multi-function relay (status signaling contact / control of self-consumption)
12
14
K1 External power control
K2
K3
K4
K5
K6 External power control / SPI frequency monitoring
*only available for the I/O module, item no. 10 005 981

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4 Installation
4�1 Storing the I/O module
Store the I/O module in the special ESD-protected bag at room temperature in a dry
location.
4�2 Checking the delivery
Check the contents of the delivered package for completeness and possible damage. In
the case of an inadequate delivery, please contact your dealer or the SolarMax Service
Center.
Installationsanleitung
SolarMax P-Serie
I/O-Modul
2 3
4
5
1
Figure 3 Content of delivery
No� Quantity Object
1 1 I/O module (packed in ESD-protected bag)
2 1 Installation manual
3 2 M3 x 8 Phillips head screw
4 3 Locking pins (for plugging unused holes in multiple cable connectors)
5 1 M25 multi-cable gland

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4�3 Installing the I/O module
The slot for the I/O module is inside the inverter.
DANGER!
Fatal electric shock hazard!
Components within the inverter are charged with mains voltage.
 Never open the inverter while it is in operation.
 Before you start installation work, ensure that all connectors and cables
are de-energized.
 Remove the cover and the contact protection on the inverter as described
in the instruction manual.
 Observe the safety instructions in the inverter instruction manual.
ATTENTION!
Damage due to electrostatic discharge!
 Avoid electrostatic discharge (ESD) when handling the I/O module.
Procedure
1. Open the inverter as described in the inverter instruction manual.
2. Remove the blind plug from the middle cable pass-through on the inverter.
3. Install the M25 cable gland on the middle cable pass-through. The M25 cable gland
is included in the delivery package.
4. Insert the I/O module.
5. Tighten the I/O module with the M3 Phillips head screws.

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4
5
Figure 4 Installing the I/O module
6. Connect the wiring to the interfaces as described in Section 4.4.
7. Complete the installation of the I/O module
– by inserting the contact protection such that you hear the snap closures engage;
– then t the cover and tighten.

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4�4 Cabling
The cabling of the I/O module passes exclusively through the middle and left cable glands
of the inverter.
WARNING!
Fatal electric shock hazard!
Cables conducting mains voltage must be covered by the contact protection
inside the inverter.
 Always route mains voltage cables through the middle cable gland
(Figure 5/Pos. 2).
1 2 3
Figure 5 Wiring of connections in the inverter
No� Description
1 Left cable gland For lightning protection monitor / S0 interface*
(energy counter)
2 Middle cable gland For external shutdown / external power control
(ripple control receiver) / SPI frequency moni-
toring / multi-function relay
3Locking pin
*only available for the I/O module, item no. 10 005981
In order to ensure that the inverter remains sealed, unused apertures in the cable glands
must be closed with the locking pins (see Figure 5/Pos 3). The locking pins are included
in the delivery package.

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4�4�1 External shutdown
This interface can be used to connect the inverter to an external grid monitoring system
which disconnects the inverter from the mains grid when this is needed.
While the external grid monitoring signal (the phase voltage) is connected to the "NA"
contact, the inverter feeds into the grid. When the signal stops, the grid relays of the
inverter are opened. This immediately disconnects the inverter from the grid.
The interface is congured with the free MaxTalk2Pro service software.
Connection conditions
 Connectable cable diameter: min. 9.5 mm / max. 12.5 mm
 Connectable conductor cross-sections: min. 0.25 mm2/ max. 2.5 mm2
 Max. input current: 25 mA
 Max. input voltage: 230 VAC
Procedure
1. Open the inverter as described in the instruction manual.
WARNING!
Fatal electric shock hazard!
Cables conducting mains voltage must be covered by the contact protection
inside the inverter.
 Always route the connecting cable through the middle cable gland
(Figure 5/Pos. 2).
2. Connect the wires as follows:
– Wire stripping length: 7 mm
Contact Description
NA Control line
NNeutral conductor
3. Close the unused holes in the cable gland using the locking pins.
4. Tighten the cable gland (wrench size: 34 mm).
5. Check the cable strain relief.
6. Close the inverter by
– engaging the contact protection;
– then tighten the cover.
You can now switch the inverter on as described in the instruction manual.

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4�4�2 External power control
Via this interface the inverter can receive digital signals for the specication of the set-
point of active and reactive power. It is possible to connect ripple control receivers to this
interface.
The interface is congured with the free MaxTalk2Pro service software.
Figure 6 shows the connection of the ripple control receiver to the interface.
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 43 2 1
a
b
c
a
b
c
a
b
c
a
b
c
a
b
c
a
b
c
K6 K5 K4 K3 K2 K1
L
(230 V)
I max = 150 mA
N
I = 25 mA
N
K5
K6 K4
K3
K2
K1NA
Ripple control receiver
Inverter
Figure 6 Connection diagram of ripple control receiver
Connection conditions
 Max. 6 relay contacts can be connected
 Max. input voltage: 230 VAC (phase)
 Connectable cable diameter: min. 9.5 mm / max. 12.5 mm
 Connectable conductor cross-sections: min. 0.25 mm2/ max. 2.5 mm2
 Input current: 25 mA
 Max. cable length: 200 m
Procedure
1. Open the inverter as described in the instruction manual.

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WARNING!
Fatal electric shock hazard!
Cables conducting mains voltage must be covered by the contact protection
inside the inverter.
 Always route the cable through the middle cable glande (Figure 5/Pos. 2).
2. Connect the wires as follows:
– Wire stripping length: 7 mm
Contact Description
K1 Control signal relay K1
K2 Control signal relay K2
K3 Control signal relay K3
K4 Control signal relay K4
K5 Control signal relay K5
K6 Control signal relay K6 (this input is not evaluated for the external output
control if the SPI logic is used at the same time)
NNeutral conductor
3. Close the unused holes in the cable gland using the locking pins.
4. Tighten the cable gland (wrench size: 34 mm).
5. Check the cable strain relief.
6. Close the inverter:
– engaging the contact protection;
– then tighten the cover.
You can now switch the inverter on as described in the instruction manual.
4�4�3 SPI logic
With this interface it is possible to connect the inverter to an external SPI frequency
monitoring device ("Segnale Esterno" is only available when "Italy" is selected in the
country setting).
The interface is congured with the free MaxTalk2Pro service software.
Procedure
1. Open the inverter as described in the instruction manual.

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WARNING!
Fatal electric shock hazard!
Cables conducting mains voltage must be covered by the contact protection
inside the inverter.
 Always route the connecting cable through the middle cable gland
(Figure 5/Pos. 2).
2. Connect the wires as follows:
– Wire stripping length: 7 mm
Contact Description
K6 Control line
NNeutral conductor
3. Close the unused holes in the cable gland using the locking pins.
4. Tighten the cable gland (wrench size: 34 mm).
5. Check the cable strain relief.
6. Close the inverter by
– inserting the contact protection;
– then tighten the cover.
You can now switch the inverter on as described in the instruction manual.
4�4�4 Multi-function relay
The multi-function relay can be used as status signaling contact for the remote control of
the inverter or for the control of self-consumption (see section 4.4.7). The conguration
as status signaling contact is either done using the inverter's graphics display (see section
5.1) or with MaxTalk2.
11
12 14
NC
Figure 7 Contact scheme of multi-function relay
Connection conditions
 Connectable cable diameter: min. 9.5 mm / max. 12.5 mm
 Connectable conductor cross-sections: min. 0.25 mm2/ max. 2.5 mm2
 Max. switching voltage: 250 VAC / 30 VDC
 Max. switching current: 1.5 A (no internal fuse present)

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 Max. cable length: 50 m
Procedure
1. Open the inverter as described in the instruction manual.
WARNING!
Fatal electric shock hazard!
Cables conducting mains voltage must be covered by the contact protection
inside the inverter.
 Always route the connecting cable through the middle cable gland
(Figure 5/Pos. 2).
2. Connect the wires as follows:
– Wire stripping length: 7 mm
Contact Description
11 COM
12 Opener (when used as status signaling contact: opener in the case of error)
14 Closer (when used as status signaling contact: closer in the case of error)
NC not used
3. Close the unused holes in the cable gland using the locking pins.
4. Tighten the middle cable gland (wrench size: 34 mm).
5. Check the cable strain relief.
6. Close the inverter by
– engaging the contact protection;
– then tighten the cover.
You can now switch the inverter on as described in the instruction manual.
4�4�5 Lightning protection monitor
This interface can be used for monitoring an external lightning protection module. The
conguration is done using the inverter's graphics display (see section 5.2.1) or with
MaxTalk2.
When the remote signaling contact of the lighting protection module connected to the
input closes, the inverter displays the corresponding status message/warning on the
graphics display. It is possible to connect multiple lightning protection modules in parallel
to the lightning protection input.
Connection conditions
 Connectable cable diameter: min. 9.5 mm / max. 12.5 mm
 Connectable conductor cross-sections: min. 0.25 mm2/ max. 2.5 mm2

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 Max. cable length: 50 m
 Do not connect any external power sources.
Procedure
1. Remove the cover of the inverter as described in the instruction manual.
– Do not remove the contact protection.
2. Route the cable through the left cable gland (Figure 5/Pos. 1).
3. Connect the wires as follows:
– Wire stripping length: 7 mm
Contact Description
BS+ Remote signaling contact of the lightning protection module
(potential-free)
BS– COM
4. Close the unused holes in the cable gland using the locking pins.
5. Tighten the cable gland (wrench size: 34 mm).
6. Check the cable strain relief.
7. Close the inverter by tting and tightening the cover.
You can now switch the inverter on as described in the instruction manual.
4�4�6 S0 interface
In accordance with DIN EN 62053-31 this interface (only available for the I/O module,
item no. 10005 981) can be used to connect an energy counter to the inverter for the
purpose of the control self-consumption. From experience, SolarMax can recommend the
following electronic energy counters: Berg MCi32WP and Berg B23 311.
Connection conditions
 Energy counters are only permitted with S0 pulses for feed-in (S0 pulses for both
directions of energy ow are not permitted).
 The pulse rate of the energy meter must be between 1 000 and 10000 pulses
per kWh.
 Connectable cable diameter: min. 9.5 mm / max. 12.5 mm
 Connectable conductor cross-sections: min. 0.25 mm2/ max. 2.5 mm2
 Max. cable length: 50 m
 Do not connect any external power sources.
Procedure
1. Remove the cover of the inverter as described in the instruction manual.
– Do not remove the contact protection.
2. Route the cable through the left cable gland (Figure 5/Pos. 1).

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3. Connect the wires as follows:
– Wire stripping length: 7 mm
– Ensure the polarity is right.
Contact Description
S0+ Pulse input (plus pole)
S0– COM (minus pole)
4. Close the unused holes in the cable gland using the locking pins.
5. Tighten the cable gland (wrench size: 34 mm).
6. Check the cable strain relief.
7. Close the inverter by tting and tightening the cover.
You can now switch the inverter on as described in the instruction manual.
4�4�7 Control of self-consumption
The inverter has functions for the control of self-consumption. Connection is via the inter-
faces of the I/O module. Several different operating modes can be selected.
Operating mode Description
Grid feed-in limitation As the inverter controls self-consumption it keeps within a max-
imum feed-in power at the grid connection point. This operating
mode is available only for the I/O module, item no. 10 005 981.
Pac electric meter The inverter controls the consumer loads in accordance with the
power fed into the grid. The power output is measured with an
energy counter. This operating mode is available only for the I/O
module, item no. 10 005 981.
Pac inverter The inverter controls the consumer loads in accordance with its
output power.

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4�4�7�1 Grid feed-in limitation
For the connection diagram in "Grid feed-in limitation" mode see Figure 8: the energy
counter that measures the power fed in at the grid connection point is connected to the
S0 interface of the I/O module.
The grid feed-in limitation is congured using the free MaxTalk2Pro service software.
S0−
S0+
BS−
BS+
12
NC
14
11
kWh
R
kWh
N
Inv
PV
°C
0
20
40
60
80
100
120
Figure 8 Wiring in "Grid feed-in limitation" operating mode
Legend: R: consumer / Inv: inverter / PV: PV generator / N: grid connection point / kWh:
energy counter
Procedure
 Connect the energy counter as described in section 4.4.6.
 Use MaxTalk2Pro to congure the max. feed-in power and the S0 interface (energy
counter).

20
4�4�7�2 Pac electric meter
For the connection diagram in "Pac electric meter" operating mode see Figure 9: the
consumer loads are controlled via the inverter's multi-function relay and a contactor. The
energy counter that measures the power fed in at the grid connection point is connected
to the S0 interface of the I/O module.
The "Pac electric meter" operating mode is congured on the inverter's graphics display
or using MaxTalk 2. The S0 interface (energy counter) is congured with MaxTalk2Pro.
S0−
S0+
BS−
BS+
12
NC
14
11
R
K
N
Inv
PV
kWh kWh
°C
0
20
40
60
80
100
120
Figure 9 Wiring in "Pac electric meter" operating mode
Legend: R: consumer / Inv: inverter / PV: PV generator / N: grid connection point / kWh:
energy counter / K: contactor, relay
Procedure
 Connect the multi-function relay as described in section 4.4.4.
 Connect the energy counter as described in section 4.4.6.
 Congure the self-consumption as described in section 5.3.1.
 Use MaxTalk2Pro to congure the S0 interface (energy counter).