Sunways AT 5000 User manual

1
User Manual
Sunways Solar Inverter
AT 2700, AT 3000, AT 3600,
AT 4500, AT 5000
english EN

2
Imprint
All rights reserved.
© Copyright by:
Sunways AG
Photovoltaic Technology
Macairestraße 3 - 5
78467 Konstanz
Germany
This user manual may only be reprinted or copied in whole or in part with the express, written approval of
Sunways AG. Any type of reproduction, distribution or storage on data carriers in any form and of any kind
not authorised by Sunways AG represents a violation of the applicable copyright laws and will be prosecuted.
We reserve the right to make technical changes which serve to improve the device, or which increase the
safety standard – even without separate prior notice.
Publisher responsible for the content: Sunways AG
This user manual contains products and product names which are registered trademarks. The mention of
products and product names is used only for information purposes and does not represent
product misuse. The passage referring to these products in this user manual does not represent original docu-
mentation of the respective product.

3
Introduction
Thank you for deciding in favour of a Sunways Solar
Inverter of the AT Series!
In doing so you have purchased an innovative, high-
quality product with unique equipment features
and a high, constant efficiency. This Solar Inverter
is equipped with HERIC® topology and innovative
FP switching, and therefore enables operation on a
large number of silicon and thin-film modules – as
accustomed from Sunways – without the use of a
transformer.
This user manual contains explanations on using the
Sunways Solar Inverter. You will learn to recognise
the many possibilities of the Solar Inverter. Informa-
tion is provided on safety, installation, commission-
ing, operation and system monitoring.
Please observe the safety precautions exactly to
ensure increased safety at the operating site of the
Solar Inverter.

4
Content
1 Product description 7
1.1 Proper use 7
1.2 Function description 7
1.3 Integration in solar system 8
Design of solar generator 8
Standard components of a solar system 9
1.4 Assembly description 9
1.5 Delivery scope 10
2 Safety precautions 11
2.1 General safety precautions 11
2.2 Explanation of symbols and warnings 12
Warnings and symbols used in this user
manual 12
Symbols used in this user manual 12
Warnings and symbols on device 12
2.3 Basic safety measures 13
2.4 Safety concept 13
3 Installation 14
3.1 Mechanical installation 14
Requirements for installation location 14
Installation 15
3.2 Electrical installation 16
Solar generator connection 16
Grid connection 20
3.3 Installing communication 22
Interface overview 22
Networking Solar Inverters via CAN bus 23
Networking Solar Inverters via RS485
interface 25
S0 interface 26
Connection of temperature and irradia-
tion sensor 26
Connecting alarm relay 27

Content
5
4 Commissioning 28
4.1 Connecting and disconnecting Solar
Inverter 28
Connecting 28
Switching off 28
4.2 Commissioning 29
Commissioning single device 29
Commissioning several networked devices 30
Later commissioning 34
5 Operation 35
5.1 Operating elements 35
Operating field 35
LCD display 35
Operating LED 35
Standard screen (single device) 36
Standard screen (system) 36
5.2 Access rights 37
Customer area 37
Installer area 37
5.3 Menu structure 38
5.4 Overview of screen displays 39
5.5 Malfunction displays 46
Solar generator fault 46
AC network fault 47
Inverter fault 49
Interface/communication fault 51
Service fault 54
6 System monitoring 55
6.1 General information 55
6.2 Integrated data logger 55
6.3 Direct Ethernet connection 56
6.4 Network settings on Solar Inverter 57
6.5 Network settings on the PC 58
6.6 Connection via an existing Ethernet
network 60
6.7 Access via DSL router 61

Content
6
6.8 Connection via the Sunways Modem 61
6.9 Dial-up connection from a PC to the
Solar Inverter 62
6.10 Sunways Browser 65
General information 65
Access protection 65
Overview – Menu 66
Language selection 66
Setting the date/time 66
Software update 67
6.11 Internet dial-up via modem 67
Modem settings 67
E-mail settings 68
6.12 Active alerting 69
General information 69
Alerting settings 69
6.13 Sunways Portal connection 70
General information 70
Setup 70
7 Appendix 72
7.1 Technical data 72
7.2 Drilling template for wall bracket 74
7.3 General liability disclaimer 75

7
1 Product description
1.1 Proper use
The Sunways AT Solar Inverter is the link between
your solar generator and the public power grid.
The energy from the connected solar generator is
converted to grid-conformant AC current and fed
into the grid.
Thanks to the HERIC® topology with FP switching,
the AT Solar Inverter has a voltage curve which
corresponds to that of a transformer device with
an earthed negative terminal, and is generally also
recognized for operation on thin-film modules.
Solar modules which require earthing of the posi-
tive terminal cannot be operated with the AT Solar
Inverter. If in doubt, always ask your module manu-
facturer about a release!
1.2 Function description
Conversion from direct into alternating current
The AT Solar Inverter converts the direct current
produced by the solar generator into alternating
current. The alternating current is then fed into the
public power grid.
Operating and display elements
Various interfaces are available for system configu-
ration and monitoring:
· Operating field (LCD display and keyboard) for
displaying operating and status values or for
inputting system parameters
· Operating LED
· Integrated web server for display and configura-
tion via a web browser
Interfaces
· Bus interface for connecting an analogue
modem, ISDN modem or GSM/GPRS modem
· Ethernet interface for connecting a PC or for
integration in existing networks
· CAN bus interface for interconnecting several
Solar Inverters
· S0 pulse output for controlling large displays
· Alarm relay for realising simple monitoring
locally
· Interface for connecting an irradiation and tem-
perature sensor
Data logging
The AT Solar Inverter is equipped with internal data
logging for recording and saving system data:
· 5-minute mean values of voltages, currents,
output, temperature and irradiation (if sensor is
installed)
· 5-minute, daily, monthly and annual values of
energy yield
· Memory for malfunction messages
Grid monitoring
The AT Solar Inverter assumes the task of grid moni-
toring for the protection of the device and persons.
In case of abnormal grid conditions, feeding is
immediately interrupted and the Solar Inverter dis-
connects from the grid by triggering the grid relay.
Design of Solar Inverter
The principle design of the AT Solar Inverters can
be recognised from the block diagram. The most
important characteristic of the inverter is the earth-
ing of the solar generator, i.e. the negative terminal
is directly connected to the neutral conductor on the
grid.
The solar generator voltage connected to the
inverter input is always positive and is initially
adapted by the DC actuator and then converted to
alternating current by the high-efficiency HERIC®
inverter.

1 Product description
8
Block diagram
=
=
=
~
L1
PE
N
L1 L2 L3 PE N
–
+
Control and monitoring
DC actuator HERIC® inverter
Solar generator
Grid
1.3 Integration in solar system
Design of solar generator
The technical data of the selected solar generator
must be within the Solar Inverter‘s specifications
(see Technical Data). Incorrect dimensioning can
lead to reductions in the yield and to destruction of
the device.
The design program Sunways Sundim may be help-
ful to you. Sunways Sundim is available on the
included CD-ROM or at our homepage
www.sunways.de.
Be sure to take the following points into account
before planning your system:
· Watch the celestial alignment of the modules.
A maximum yield is achieved in Central Europe
with a module slope of 30° to the vertical and
direction of the solar generator field directly to
the south.
· The output of the cells decreases as the module
temperature increases. Install your solar genera-
tor with sufficient ventilation from behind.
· Check your solar generator approx. every three
years for soiling. This occurs especially on the
lower edge of the modules and forms a veil
that cannot be washed off even by heavy rain.
Reduced yield can be prevented by cleaning with
a wet cloth or a brush.
· Avoid switching off individual modules or solar
cells of your system. This can lead to major
decreases in yield.

1 Product description
9
Standard components of a solar system
Depending on the recommendations of your PV
planning expert, your PV system consists of the fol-
lowing components:
1
4
5
2
3
6
DC
AC
1 Solar generator
2 Solar Inverter with integrated DC load break
switch
3 Mains fuse and energy meter
Options
4 Irradiation sensor with integrated temperature
sensor
5 PC for monitoring system
6 Large display
1.4 Assembly description
350
585
205
+–
+–
1
2
2 3 4 5
6
1
87 9 13121110
6
1 Operating field with LCD display, operating LED
and keyboard
2 DC connections
3 DC load break switch
4 Rating plate
5 AC connection
6 Communication interfaces

1 Product description
10
1.5 Delivery scope
The delivery consists of:
· Sunways Solar Inverter of the AT-Series
· Installation frame
· 2 pairs of Tyco Solarlok plug-in connectors
· AC connector
· CAN terminating resistor connector (connected)
· Ethernet cable, 2 m (CAT 5e, 1:1)
· Warranty card
· Setup
· CD-ROM, including: Manual, Sunways Sundim
design program, product and service information
Checking delivery
Before shipment our products are checked for
proper condition. Despite careful, recyclable pack-
ing, transport damage may occur, for which the
transport company is generally responsible.
Please check the delivered Solar Inverter thoroughly!
Should you discover damage to the packing or the
Solar Inverter, please inform the transport company
immediately. Your specialist dealer will be happy to
support you if necessary. A possible damage report
must always be received by the transport company
in writing at the la-test seven days after receipt of
the goods.

11
2 Safety precautions
2.1 General safety precautions
Observe information in operating manual!
The condition for the safe handling and malfunc-
tion-free operation of the AT Solar Inverter is a
knowledge of the basic safety precautions.
This user manual contains the most important infor-
mation on operating the system safely.
Each person concerned with the installation, com-
missioning, maintenance and operation of the Solar
Inverter must have read and understood the entire
user manual, and in particular the chapter entitled
Safety Precautions.
In addition, the rules and regulations for accident
prevention applicable for the operating site/plant
must be observed.
Dangers when handling the AT Solar Inverter
The Solar Inverter has been built in accordance with
the latest rules of techno-logy and the recognized
safety rules and may only be used
· for its intended use
· when in proper condition with regard to safety.
Improper use may lead to dangers to the life and
limb of the user or others, or can adversely affect
the system or other property.
In case of malfunctions which can impair safety, the
system must be shut down immediately and secured
against being switched on again. The malfunction
must then be eliminated immediately.
Warranty and liability
The Sunways AG „General Terms and Conditions of
Sale and Delivery« always apply. Warranty and liabil-
ity claims for personal injury or damage to property
are excluded, if they were caused by one or more of
the following:
· Improper use of the Solar Inverter
· Improper installation, commissioning, operation
and maintenance
· Operation of the Solar Inverter with defective
and/or non-operational safety and protective
equipment
· Failure to observe the information in the user
manual regarding installation, commissioning,
operation and maintenance
· Unauthorised constructional modifications
· Insufficient monitoring of wearing parts
· Improperly conducted repairs
· Emergencies caused by external influence or
force majeure

2 Safety precautions
12
2.2 Explanation of symbols and warnings
To help you quickly understand this manual and
safely use the Solar Inverter, the following warnings
and symbols are used.
Warnings and symbols used in this user manual
DANGER
This symbol indicates an immediate danger which
will result in death, injury or serious damage if the
applicable safety regulations are not followed.
Extreme danger from electric shock!
This symbol indicates an immediate danger from
electric shock which will result in death, injury or
serious damage if the applicable safety regulations
are not followed.
CAUTION
This symbol indicates an immediate danger which
can result in damage if the applicable safety regula-
tions are not followed.
Symbols used in this user manual
Information
This symbol indicates important information which
contributes to a better understanding of the Solar
Inverter.
Warnings and symbols on device
The following warnings on the housing of the Solar
Inverter point out dangers. Always observe the
warnings exactly.
This symbol indicates that the user manual must be
read and understood before putting the device into
operation.
IMPORTANT
Hot surface! The housing can heat up during
operation.
The device must be disconnected from the mains
supply and from the PV generator before opening
the housing. The device still carries life-threatening
voltage for approx. five minutes internally and at
the connection terminals of the PV generator fol-
lowing disconnection from the PV generator. The
energy storage capacitors are not completely dis-
charged until after this time. You must wait at least
five minutes after disconnecting the device from
the mains supply and from the PV generator before
opening the device.
Warning!
High leakage current,
earth connection essential before
connecting supply.
WARNING!
High leakage currents. Be sure to make an earth-
ing connection before connecting the power supply
circuit (AC system).

2 Safety precautions
13
2.3 Basic safety measures
Electrical work on the Solar Inverter must be con-
ducted by a qualified electrician while observing the
VDE regulations, national and other regulations.
The Solar Inverter may only be opened by persons
authorised by Sunways AG to do so.
When circuit breakers are tripped, the fault cause
must be determined and eliminated before return-
ing the device to operation.
Check electrical equipment regularly.
Retighten loose connections.
Replace damaged lines/cables immediately.
2.4 Safety concept
The following parameters are monitored and
displayed continuously and simultaneously by the
inverter controller:
· DC overvoltage
· Overvoltage L1, L2, L3
· Undervoltage L1, L2, L3
· Isolated operation
· Over- / underfrequency L1
· Surge error (brief overvoltage L1)
· DC share in AC current
· AFI residual current
· Overtemperature of heat sink
When a malfunction occurs, feeding is immediately
interrupted and the Solar Inverter disconnects from
the grid by triggering the grid relay.
The potential-free alarm relay is switched (except
for grid undervoltage L1).
In addition, the following protective equipment in
accordance with overvoltage category III is provided
on the grid and on the solar generator side:
· Grid-side varistors
These protect the power semiconductors in case
of high-energy, short-term voltage peaks in the
grid and provide for an energy reduction in reac-
tor in case of a grid disconnection.
· Generator-side varistors
Varistors offer protection against atmospheric
overvoltages (e.g. caused by remote strikes dur-
ing thunderstorms).

14
3 Installation
3.1 Mechanical installation
Requirements for installation location
DANGER
· The Solar Inverter may not be installed in rooms
subject to explosion hazards.
· The Solar Inverter may not be exposed to caustic
gases!
· No combustible or highly flammable materi-
als may be stored within 3 metres of the Solar
Inverter.
Protection against moisture and foreign bodies
The high protection type IP 54 allows installation
indoors and in roof-covered areas outdoors, how-
ever the Solar Inverter may not be directly exposed
to rain.
Mechanical load-bearing capacity
Note during installation that the Solar Inverter
weighs 29 kg. The installation surface must be firm
and able to carry this weight in the long term.
Thermal interaction
· The installation surface must consist of flame-
retardant material (not suitable: surface of wood
or plastic; suitable: concrete and masonry), as
the frame of the Solar Inverter can heat up to a
maximum of 70°C.
· A minimum distance of 300 mm to other devices,
cabinets, ceilings, cable ducts, etc. must be
maintained above, below and to the sides of the
housing. See the figure Requirements for instal-
lation location.
· The Solar Inverter must be installed vertically to
enable sufficiently free convection.
· Several Solar Inverters may not be mounted over
each other to prevent them from heating each
other.
· Ensure sufficient heat dissipation when installing
the Solar Inverter in a switch cabinet or closed
room.
· The ambient temperature may not drop below or
exceed -25°C and +40°C respectively. At ambient
temperatures above 40°C, the inverter automati-
cally reduces its output.
· The Solar Inverter must not be exposed to direct
sunlight, to protect it from unnecessary external
warming.
300 mm 300 mm
300 mm
300 mm
Wall
Ceiling
Cold
air
Hot
air
>300 mm
>350 mm

3 Installation
15
Installation
Proceed as follows to install the Solar Inverter:
1. Hold the wall bracket at the point at which you
want to attach the Solar Inverter and mark the
mounting holes.
2. Drill the holes with a 10 mm dia. drill bit. A drill-
ing template with exact dimensioning can be
found in the appendix.
3. Install the wall bracket with corresponding
screws and dowels depending on the surface
condition.
4. Unscrew the locking screw of the Solar Inverter
at the lower left with an Allen key
5. Hook the Solar Inverter into the cut-outs of the
installation frame at the top on both sides.
6. Secure the Solar Inverter by tightening the lock-
ing screw.

3 Installation
16
3.2 Electrical installation
Solar generator connection
Extreme danger from electric shock!
· Touching live parts can result in death.
· All electrical work must be conducted by a quali-
fied electrician while observing the VDE regula-
tions, national and other regulations!
· Execute the direct current wiring in accordance
with the system dimensioning of your planning
expert.
· Prepare all solar generator cables before you
carry out the connection of the solar generator
to the Solar Inverter.
· Check each solar generator string for proper
operation with an open-circuit voltage and
short-circuit current measurement.
· Check using the rating plate on the Solar Inverter
whether it is approved for the maximum solar
generator voltage.
· The positive and negative lines must be kept
electrically separate from the earth potential.
· Touchable, live parts of the solar generator (e.g.
metal frame, carrying structure, etc.) must be
earthed (connection with PE).
· Check the solar generator against short-circuits
to earth.
· Before connecting the solar generator to the
Solar Inverter, the integrated DC load break
switch must be opened quickly (position 0).
· After the PV solar generator is connected to
the Solar Inverter and the DC load break switch
is switched on, the direct generator voltage is
present internally.
· The connectors may not be separated while
under load.
· Always separate the grid connection first by
switching off the corresponding mains fuse and
then the solar generator side by quickly opening
the DC load break switch.
Survey
The solar generator can be directly connected to the
Solar Inverter with two strings. The connection is
made via the shockproof Tyco Solarlok plug-in con-
nection system accessible from outside.
The Solar Inverter has two electrically connected
DC inputs, which are arranged in pairs on the
underside.
· The solar generator strings must be identically
dimensioned and comply with the specifications
of the Solar Inverter.
· No external DC load break switch is required. A
DC load break switch as required in accordance
with DIN VDE 0100-712 is integrated in the Solar
Inverter.
+–
+–
1
2
3– +
1 Connection of solar generator string 1
2 Connection of solar generator string 2
3 DC load break switch

3 Installation
17
Tyco Solarlok plug-in connection system
The Solarlok plug-in connection system is used for
the simple, reliable connection of individual solar
generators up to the Solar Inverter.
Components
The following connectors are used:
· Positively coded connector
· Negatively coded connector
· Neutral connector
The neutral connector can be used to connect both
positively and negatively coded sockets.
Installation
Extreme danger from electric shock!
· Touching live parts can result in death.
· All electrical work must be conducted by a quali-
fied electrician while observing the VDE regula-
tions, national and other regulations!
· Tyco Solarlok connectors are only reliable for
connection on permanently installed lines.
· Only the Tyco-Solarlok hand crimping pliers may
be used to crimp the connectors.
· During preassembly, the connectors must be
separated from all other voltage sources.
· The connectors may not be separated while
under load. The circuit must be opened at a suit-
able point for this purpose.
· Provide the lines with corresponding stickers as
close as possible to the connectors to prevent
confusion.
· Any kind of soiling (dust, moisture, etc.) has a
negative effect on the connector system with
regard to function over the intended period of
use. This particularly applies to the suitability for
use of the seals and the crimping of the con-
tacts. Therefore, extreme care must be taken to
achieve proper processing during assembly.
· Various circular contacts are used for different
conductor cross-sections with the Tyco Solar-
lok connectors. The correct tool insert must be
used in accordance with this cross-section. The
included Tyco Solarlok connectors are equipped
with circular contacts for a cable cross-section of
4 mm² to 6 mm².
· The seals and clamping baskets used in the
preassembled connectors are approved for cable
sheath diameters from 4.5 mm to 6.9 mm. Special
seals and clamping baskets must be used for
cables with a sheath diameter greater than
6.9 mm.
· The Tyco Solarlok hand crimping pliers can be
purchased from your sales partner.

3 Installation
18
The following sequence must be observed during
assembly:
1. Stripping the voltage-free line.
8
2. Crimping on the circular contact with the Tyco
Solarlok hand crimping pliers.
3. Sliding the cable gland onto the line and engag-
ing the contact in the connector housing.
4. Tightening the cable gland with 1.5 Nm.
Handling
The positively/negatively coded connectors are
marked with polarity symbols and a coloured ring
(blue = negative, red = positive). They are equipped
with coding ribs for assignment, which ensures that
only connectors of the same polarity can be con-
nected to each other.
Connecting socket and plug. The system is only cor-
rectly locked if the locking hooks are recessed flush
in the mating piece.
CAUTION
The connectors may not be separated while under
load. The circuit must be opened at a suitable point
for this purpose.
Release the locking device by pressing on the rib-
bing of the locking hooks and pulling them apart.

3 Installation
19
Connection example
2
3
5
4
5 2 5 2
2 4
111
6
– –NN
N
+
–
–
+–
1 Solar module box
2 Negatively coded socket
3 Negatively coded plug
4 Positively coded socket
5 Neutral connector
6 Solar inverter

3 Installation
20
Grid connection
Extreme danger from electric shock!
· Touching live parts can result in death.
· All electrical work must be conducted by a quali-
fied electrician while observing the VDE regula-
tions, national and other regulations!
· Observe the pin assignment of the AC bayonet
connector. An incorrect assignment can result in
the device being destroyed.
· No consumers may be connected to the supply
line from the Solar Inverter to the mains fuse.
· Always separate the grid connection first by
switching off the corresponding mains fuse and
then the solar generator side by quickly opening
the DC load break switch.
If the voltage on the AC connection exceeds the
permissible value due to a long line length or an
insufficient cable cross-section, the Solar Inverter
will disconnected from the grid. In power grids with
a low output and a high solar generator output, this
can lead to individual Solar Inverters being switched
off and then on again several times.
Survey
An AC bayonet connector on the underside of the
unit is used for the three-wire grid connection (L, N,
PE) of the Solar Inverter. The grid connection should
always be 1-phase. Feeding is single-phase via AC
terminal 2.
+–
+–
12
1 DC load break switch
2 AC connection
A basic distinction is made between two different
connection options of the Solar Inverter to the pub-
lic power grid:
· 3-phase AC grid (e.g. Germany)
· 1-phase AC grid (e.g. Italy, Spain)
CAUTION
· Observe the regional regulations for the grid
connection.
The Solar Inverter always only feeds via AC terminal
2. If several Solar Inverters are operated in parallel
in a 3-phase grid, AC terminal 2 of the device must
be distributed uniformly among the grid phases L1,
L2 and L3 to avoid unequal loading.