SolarMax TS Series User manual

SolarMax TS-Serie
50TS/ 80TS/ 100TS
Gerätedokumentation Instruction manual Documentation d’appareil
Documentación del dispositivo Documentazione dell’apparecchio

63
Content
1 About this instruction manual 65
1.1 Target group 65
1.2 Where to keep this manual 65
1.3 Symbols used 65
2 Safety instructions 66
2.1 Appropriate use 67
3 Description 67
3.1 Block circuit diagram 68
3.2 External operating elements and dimensions 69
4 Installation 70
4.1 Transport and storage 70
4.2 Siting 70
4.3 Lightning protection 72
4.4 Scope of delivery 72
4.5 Inside view 73
4.6 Electrical connection 74
4.6.1 Mains fuses and minimum line cross-sections AC 74
4.6.2 Minimum line cross-sections DC 74
4.6.3 DC and AC terminals 75
5 Commissioning 82
5.1 Switching on and off 82
5.2 Initial start-up (Initial Setup) 83
6 Operation 85
6.1 Graphics display 85
6.2 Menu button symbols 85
6.3 Menu structure 86
6.3.1 Main menu 86
6.3.2 Overview 88
6.3.3 Measured values 88
6.3.4 Statistics 89
6.3.5 Conguration 92
6.3.6 Settings 94
6.3.7 Information 97
7 Data communication 98
7.1 Conguration of the data communication interfaces 99

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8 Options 100
8.1 MaxControl 100
8.1.1 Scope of services 100
8.1.2 Duration 100
8.2 Accessory components 100
9 Operating status 101
9.1 Status messages and status LED 101
9.3 Mains operation 102
9.4 Communications activity 103
10 Troubleshooting 104
10.1 SolarMax Service Centre 105
10.2 Diagnosis & measures 106
10.2.1 General troubleshooting 106
10.2.2 Warnings 106
10.2.3 Failures 107
10.2.4 Error 108
10.2.5 Blockings 108
10.2.6 Error messages during the initialisation phase 109
11 Maintenance 109
11.1 Maintenance by a qualied electrician 110
11.2 Maintenance by the plant operator 110
12 Disposal 110
13 Specications 111
13.1 Specications 111
13.2 Efciency curve 113
13.3 Power derating 114
13.4 Individual country settings 115
14 Guarantee 120

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1 About this instruction manual
This instruction manual contains a description of the 50TS, 80TS and 100TS SolarMax
central inverters. It also tells you how to install, commission and operate the inverter.
Familiarize yourself with inverter functions and characteristics before you begin the in-
stallation work. Carefully read the safety instructions in this manual. Ignoring the safety
instructions can result in serious injuries or death.
1.1 Target group
This instruction manual is written for the operator of the PV plant and the responsible
qualied electrician.
1.2 Where to keep this manual
The system operator must ensure that this instruction manual is available to those
responsible for the power plant at all times. If this original document is lost, an up-to-date
version of this instruction manual can be downloaded from our website at all times (www.
solarmax.com).
1.3 Symbols used
From time to time you will see the following symbols when reading this instruction manual:
DANGER
This symbol indicates that ignoring this instruction may directly lead to serious
injury or death.
CAUTION
This symbol indicates that ignoring this instruction can lead to damage to your
inverter or your PV power plant.
NOTE
This symbol indicates information which is especially important for operating
the inverter.

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2 Safety instructions
The design of the TS series inverters reect the latest advances in the eld and they
have been tested to meet current product safety standards. However, ignoring the safety
instructions contained in this instruction manual can endanger the user, a third party or
property. The qualied electrician and the operator of the PV power plant can reduce
these risks to a minimum by following the safety instructions at all times.
DANGER
Only qualied electricians who have already completely read and understood this
instruction manual in advance may install and open SolarMax inverters.
The responsible electrician shall be responsible for complying with the applicable
local installation and safety regulations.
Ignoring the installation and safety instructions shall forfeit any and all warranty
and liability claims.
Touching live parts is life-threatening.
The inverters must remain closed at all times during operation.
Before the inverter is opened, the DC and AC feed lines must be disconnected
according to the instructions and secured against being reconnected accidentally.
After disconnecting the inverter wait at least 5 minutes before opening the device
to permit internal capacitors to discharge.

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2.1 Appropriate use
The SolarMax TS series inverters are designed exclusively to convert the direct current
generated by PV modules into alternating current which conforms to the parameters of
the public grid. Any other use is contrary to the purpose for which the inverters were
designed. Sputnik Engineering accepts no liability for damages resulting from using in-
verters for purposes other than this. Any modications to the inverter performed by the
plant operator or the tter without any review or approval by Sputnik Engineering are
prohibited.
3 Description
The central inverters of the SolarMax TS series convert the PV generator’s direct current
into alternating current which conforms to public grid parameters. The current fed into the
grid through a 50 Hz transformer is three phase.
The control unit of the TS series has two digital signal processors (DSP) which do all
the monitoring, controlling and regulating. All the safety-relevant values are continuously
monitored and compared by both processors. The result is greater operating safety and
reliability. The DSP’s high performance enables precise and rapid identication of the
maximum power points (MPP) of the PV generator and, combined with the low-loss power
unit, delivers maximum yields. The completely digital regulation ensures an outstanding
quality of the current fed into the grid which ensures negligible grid reactions.
The inverters are capable of delivering reactive power if necessary to actively support
the grid during short blackouts as well as of receiving and implementing remote control
commands (power output reduction, etc.).
The TS series is operated using a graphic LC display and three push-buttons. Integrated
RS485 and Ethernet interfaces enable many communications and monitoring options
based on our MaxComm communications platform. The system communicates either
directly via a PC or the Internet-enabled MaxWeb xp data logger.
All SolarMax inverters work completely automatically. The DC and AC power switches
(Q1 and Q2) as well as the main switch (Q3) are always on during normal operation. The
inverter starts when there is enough input power and continues to operate until the avail-
able input power from the PV generator drops below the necessary minimum.

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3.1 Block circuit diagram
AC Output
3 x 400 VAC
EMC Filter
AC-Switch Q2
LC
Filter
RS485 / Ethernet
EMC Filter
DC Input Max. 900 VDC
DC-Switch Q1
Display
U
K1 3
2
ON
OFF
Control Unit
Fan Control
Status-Relay
Test-Terminal
Inverter Shutdown 1
Inverter Shutdown 2
Ext. Alarm
Inverter Control
Main Switch Q3
AC Measurement
DC Measurement
Inverter
SolarMax TS-Series Inverter

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3.2 External operating elements and dimensions
80
40 20
80
56
392
1000
760
60080 80
392
1410
Display and
operating unit
DC and AC
power switch

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4 Installation
4.1 Transport and storage
During transport, attention must be paid to the following aspects:
The inverter must be transported vertically (in normal orientation) and must never be
tilted.
During transport and any interim storage period you must ensure that the ambient
conditions (temperature and humidity) are always within the tolerance limits specied
in the technical data. A longer term, unattended and unprotected interim storage of the
inverter in the open must be avoided at all costs.
4.2 Siting
Choosing a suitable location for the inverter is decisive for its operating safety as well as
its expected service life and efciency.
An ideal location is indoors, in a plant room which is:
DANGER
Lockable
The plant room must be lockable to protect the inverters from unauthorised access.
Free from any combustible or explosive materials, gases or vapours
The inverters must not be installed in rooms or on business premises endangered
by re and the local re-prevention guidelines must be obeyed. The inverters must
not be installed on or in proximity to combustible materials.
Make sure that the oor of the installation location offers sufcient bearing capac-
ity.

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CAUTION
Dry
The formation of condensation within a SolarMax inverter must be avoided: There
must be no puddles, damp masonry walls or similar sources of humidity in the vi-
cinity of the device. Plant rooms which are not effectively protected against water
or snow are not suitable as installation locations.
CAUTION
Dust-free
The inverter must be operated in a room with as a little dust as possible to prevent
avoidable accumulations of dust on the heat sinks and fans. Rooms with heavy
concentrations of dust (e.g., carpentries or metal construction shops) are not suit-
able installation locations.
The installation location must meet the requirements contained in the standard for
electromagnetic immunity for industrial environments (EN 61000-6-2) and for
emissions in industrial environments (EN 61000-6-4).
To ensure that the inverter is accessible for possible repair work the front side must
be at least 1 m away from the nearest object (wall, other inverters, etc.). Do not
install the inverter on a raised surface, platforms or consoles.
Do not install the inverter where the ambient air contains salts or ammonia.
NOTE
Due to possible noise we do not recommend installation in or near residential
rooms or workplaces.
Please remember that the inverter and any existing accessories give off heat during
operation which can contribute to a serious heating up of the ambient air if the plant
rooms are small or poorly ventilated. If the conditions in your plant room could lead
to an unacceptable heating of the ambient air (Tambient air > 50 °C) then the instal-
lation of an additional ventilation system is necessary. Our basic rule is always to
recommend that the ambient temperature be kept under 30 °C. Each inverter
needs 1500 m3of fresh air per hour.
The inverter’s heat sinks are actively cooled by internal fans. The cool, fresh air enters the
inverter from below, is drawn in by the fans and is blown upwards through the ventilation
screens out of the inverter.
For safety reasons the temperature of the heat sink is limited to 85 °C. At ambient
temperatures of more than 45 °C the heat sink temperature may reach 80 °C. If this hap-
pens, the maximum feed output is temporarily reduced and a corresponding status mes-
sage appears on the inverter’s display screen. But if the temperature still runs as high as
85 °C the inverter is shut down to prevent a thermal overload.

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4.3 Lightning protection
The requirements for appropriate lightning protection for a PV power plant depend
on many different factors (plant size, how the cables are run, the modules used, the
surroundings, etc.). A project-specic protection concept must be developed by a quali-
ed person.
4.4 Scope of delivery
Inverter
4 x perforated grid front/back
2 x perforated grid lateral
12 x slotted screws M6 x 12 incl. spring washers for installing the perforated grids
EMC kit: 4 ferrite cores (only for inverters with the item numbers 8141-2, 8151-2,
and 8161-2)
Instruction manual

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4.5 Inside view
Open the inverter by removing the two M5 screws including the serrated washers. Keep
the screws and serrated washers in a safe place as long as you have the inverter open.
Legend:
1AC terminals 5Power unit
2DC terminals 6Graphic display
3AC power switch (Q2) 7Main switch (Q3)
4DC power switch (Q1) 8Terminal block
1
2
3
4
5
7
8
6

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4.6 Electrical connection
DANGER
Before you start the installation work, make sure that all the provided DC and AC
feed lines to the inverter are de-energised. The installation work must be per-
formed by a qualied electrician who adheres to the recognised rules of electrical
installations and personal health and safety regulations.
All the feed lines to the inverter must be appropriate for the expected voltages,
currents, and ambient conditions (temperature, UV load, etc.). Make sure that all
lines are laid tension-free.Make sure that all lines are laid tension-free.
NOTE
The DC inputs of the inverter are overvoltage protective Type 3. The AC end of the
inverter has no built-in overvoltage protection.
4.6.1 Mains fuses and minimum line cross-sections AC
The following table states recommended mains fuses and minimum line cross-sections
for AC feed lines:
50TS 80TS 100TS
Mains fuses
(characteristic D) 125A 125A 160A
Minimum line
cross-section AC 50 mm250 mm270 mm2
4.6.2 Minimum line cross-sections DC
The minimum required line cross-sections for the DC lines depend on how many DC
terminals are actually used. The following table states the minimum required line cross-
sections (per line) when one, two or three DC feed lines are in use.
Number of feed
lines used
50TS 80TS 100TS
1 50 mm295 mm295 mm2
2 35 mm250 mm250 mm2
3 35 mm270 mm270 mm2

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The cross-section requirements in the case of three feed lines are greater than for two
feed lines since if there is a short circuit on the DC end, the two intact feed lines pass on
all the return current to the defective line.
The cross-section increase for 3 DC feed lines can be done without if all the DC feed lines
are fused.
If the feed lines are particularly long we recommend you use larger line cross-sections to
keep transmission losses as low as possible.
4.6.3 DC and AC terminals
DC+ DC+ DC+ DC- DC- DC- L1 L2 L3 N PE
DC terminals
The DC terminals allow the connection of as many as 3 (3 plus and 3 minus each) DC feed
lines from the PV generator with a cross-section of up to 150 mm2.
Insert the DC feed lines by removing the terminal’s M10 Allen screw and inserting the cable
from below into the terminal. Then tighten the Allen screw rmly (min./max. Torque 25/
30 Nm).
Installation of the ferrite cores (EMC kit)
Regarding the inverters with the item numbers 8141-2, 8151-2, and 8161-2, you must
install the supplied ferrite cores of the EMC kit. Please proceed as follows:
Guide all AC feeder lines through the 4 ferrite cores. Position the 4 ferrite cores at a
distance of 15 – 20cm to the AC terminals. There is no need to attach the ferrite cores.
Connect the AC feeder lines as described in the following section.

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L1
15…20 cm
L2 L3 N PE
4 ferrite cores (EMC kit)
AC terminals
At the AC terminals rst the protective earth (PE) connection must be connected, and
then the 3 AC phases (L1, L2 and L3). Remember that the rotating eld of the mains
phases to be connected must be clockwise. The connection of the neutral conductor N
is optional and not necessary for safe and proper inverter operation. The maximum con-
nectible line cross-section is 95 mm2.
NOTE
TS series central inverters do not need a neutral conductor.
Insert the AC feed lines by removing the terminal’s M8 Allen screw and inserting the cable
from below into the terminal. Then tighten the Allen screw rmly (min./max. Torque 15/
20 Nm).
4.6.4 Terminal block
All the external interfaces of the TS series inverter are on the terminal block.
The following interfaces are available:
Shutdown contact 1 SD1 / SD2 / SD3 / SD4
External alarm contact STM / GND
Shutdown contact 2 EN1 / EN2
Status signalling contact FR1 / FR2
Test contact U L1 / U L2 / U L3 / K1 EN
Service contact K1A2
Data communications sockets Ethernet/RS485

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Overview terminal block
SD1 SD2 SD3 SD4 STM GND EN1 EN2 FR1 FR2 U L1 U L2 U L3 K1EN K1A2 F L1
F L2
F L3 Ethernet/ RS485 RS485
Recommendation regarding line cross-sections
For the correct wiring of the status, alarm and shutdown contacts we recommend the
following line cross-sections:
Minimum cross-section: 0.75 mm2
Maximum cross-section: 4 mm2
Maximum cable length: 50 m
Status signalling contact - FR1 / FR2
The status signalling contact is used for the remote monitoring of the inverter. The in-
verter status can be recorded with the potential-free relay contact.
The functionality of the status signalling contact is adjustable, see section “Status relay”:
page 93.
Specications of the status signalling contact
Contacts potential-free (make contact), not fused
Max. switching voltage: 250 VAC / 100 VDC
Max. switch current: 5 Aeff @ 250 VAC / 30 VDC
Continuous current: 2 Aeff

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Shutdown contact 1 - SD1 / SD2 / SD3 / SD4
The shutdown contacts 1 (SD1-SD4) enable remote shutdown of one or several TS series
inverters using an external break contact.
If the shutdown function 1 is activated the current supply circuit of the AC contactor K1
is disconnected directly and the inverter is locked. This results in the immediate discon-
nection from the grid which is also effective when the control unit fails. The inverters
remain locked until the external break contact is re-closed. In addition, the status mes-
sage “Shutdown 1” is displayed.
The shutdown 1 is inactive if there is a short circuit between either the contact pair SD1
and SD2 (SD12) or SD3 and SD4 (SD34), e.g., with a plaited bridge. The shutdown 1 is
only active if both contact pairs SD12 and SD34 are open.
When shipped from the factory the contact pair SD12 is short-circuited with a plaited
bridge.
If you want to lock several inverters (as many as 20) with a single break contact, wire the
shutdown contacts 1 as shown in the following schematic with a suitable two-wire cable:
Wiring for shutdown contact 1
S
D
1
S
D
2
S
D
3
S
D
4
S
D
1
S
D
2
S
D
3
S
D
4
S
D
1
S
D
2
S
D
3
S
D
4
Inverter 1 Inverter 2 Inverter 20
Break contact

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External alarm contact - STM / GND
The alarm contact is used to be able to display the status of a MaxConnect plus genera-
tor connection box in the inverter display unit. For this purpose use a two-wire cable to
connect the contacts of the potential-free fault alarm output of MaxConnect plus to the
STM and GND contacts on the inverter’s terminal block. As soon as the STM and GND
contacts are short-circuited, the inverter display shows the status message “Warning
MaxConnect”.
Shutdown contact - 2 EN1 / EN2
The shutdown contacts 2 (EN1 and EN2) enable remote shutdown of one or several TS
series inverters using an external break contact. The function is similar to the one of
shutdown contact 1, but the separation from the grid is not made directly via the supply
voltage of the AC contactor K1. It is controlled by software via the inverter’s control unit.
The inverters remain locked until the external break contact is re-closed. In addition, the
status message “Shutdown 2” is displayed.
The shutdown 2 is inactive if there is a short circuit between the contact pair EN1 and
EN2 (EN12), e.g., with a plaited bridge. The shutdown 2 is active if the contact pair EN12
is open.
Test contact U L1 / U L2 / U L3 / K1 EN
The test contacts permit a separation of the measuring lines between the inverter’s con-
trol unit and the three phase voltages U L1, U L2 and U L3. In addition, the power supply
circuit for the AC contactor K1 can be disconnected. This allows a function test of the
mains monitoring of the inverter to be carried out with an external voltage source.
DANGER
Disconnect the inverter from the mains with the AC power switch Q2 before carrying
out the test. Since to conduct the tests described below the inverter must be supplied
with enough power by the PV generator (DC power switch Q1 switched on), inverter
components are exposed to high DC voltages. When you conduct this test you must
be extremely careful!

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How to conduct the test
1. Open the AC power switch Q2 (position “OFF”)
2. Make sure that the inverter is supplied with enough power by the PV generator to
conduct the test. Do not conduct the test shortly before sunset or at times when irra-
diation levels are weak or wildly uctuating.
3. Loosen the slide switches fastened with slotted screws of the test contacts U L1, U L2,
U L3 and K1EN.
4. Slide all the slide switches upwards and secure them in position by re-tightening the
slotted screws.
5. Then connect the 3-phase generator to the test contacts U L1, U L2 and U L3. Only use
the upper 4 mm sockets on the test contacts. Make sure that the rotating eld of the
generator phases is connected clockwise.
6. Connect a suitable DC voltmeter to the upper and lower test contact K1 EN.
7. Switch on the generator. The external conductor voltages must correspond to the
nominal mains voltage and frequency (3 x 400 VAC / 50Hz).
8. The inverter starts and switches after roughly 30 seconds to (simulated) mains opera-
tion.
9. The control voltage of the AC contactor K1 is now 24 VDC.
10. Now increase the voltage or the frequency of any one phase to under the pre-set
tolerance value (see the table in 13.4 entitled Individual Country Settings).
CAUTION
Never set the test voltage higher than 520 V (130 % of the nominal voltage). This can
damage the inverter’s measurement circuits. Sputnik Engineering assumes no liability
for damages which result from incorrectly conducted tests.
11. If you now increase the phase voltage or the frequency beyond the tolerance value,
the inverter’s mains monitoring system must react the control voltage of contactor
K1 drops to 0 V.

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U L1 U L2 U L3
K1EN
K1A2
4 mm jack sockets to
the control unit
4 mm jack sockets to
the AC connections
The test is completed when the control voltage of the protection drops. During normal
inverter operation, you must separate the generator and the voltmeter from the inverter
and return the orange slide switches back to their lower positions and fasten them in
place. Then, re-connect the inverter to the mains by switching on the AC power switch Q2.
Service contact - K1A2
The service contact is exclusively for use by Sputnik service personnel and must not be used
by the installing electrician or the plant operator.
Data communications sockets - Ethernet/RS485
The two RJ45 sockets on the terminal block are data communications interfaces for the
inverter. You can connect the inverter with these two sockets to MaxComm communications
network and use the extensive monitoring and remote control options offered by Sputnik
Engineering. Further information about the advantages of the MaxComm communications
platform can be found in the section “Data communications”.
The function of the left RJ45 socket can be set in the “Settings” menu to either Ethernet
or RS485. The right-hand RJ45 socket always functions as a RS485 socket.