ZCS 3K-6K TLM LITE Series User manual

Identificazione: MD-AL-GI-00 Rev. 4.0 del 31.01.18 - Applicazione: GID
Reg. Pile IT12110P00002965 - Capitale Sociale € 100.000,00 I.V.
Reg. Impr. AR n.03225010481 - REA AR - 94189
Azienda Certificata ISO 9001 - Certificato n. 9151 - CNS0 - IT-17778
Zucchetti Centro Sistemi S.p.A. - Green Innovation Division
Via Lungarno, 248 - 52028 Terranuova Bracciolini - Arezzo, Italy
tel. [phone] - fax. [phone]
[e-mail] - [email protected] –www.zcsazzurro.com
Grid-connected inverter
3K –6K TLM LITE
User Manual
V2.1 (07-06-2019)

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Table of Contents
1. Preliminary safety instructions………………………………………...…….…………………………………………………………….6
1.1. Safety instructions…..………………………………………………………..……………………………………………………………6
1.2. Symbols and icons……………………………………………………………….…………………………………………………………9
2. Product features……………….……………………………………………………….………….……………………………………………10
2.1. Product presentation……….…………………………………………………...……………………………………………………..10
2.2. Description of functions……………………………………………………………………………………….……………………....11
2.3. Protection of modules………………………………………………………………..…………………………………………………12
3. Installation..………………………………………………………………………………………………………………………………………14
3.1. Installation process………………………………………………………………………...……………………………………………14
3.2. Checks before installation……………………………………………………………………………………………………………14
3.3. Installation tools…………………………………………………………………………….……………………………………………16
3.4. Installation position………………………………………………………………………….….………………………………………18
3.5. Moving the ZCS 3-6 K TLM L inverter……………………………………………………….……………………………………19
3.6. Installing the ZCS 3-6 K TLM L inverter.……….………………………………………………………..………………………20
4. Electrical connections.……………..…………………………………………………………………..……………………….…………….21
4.1. Electrical connections.……………..…………………………………………………………………..……………………….………22
4.2. PNGD cable connections.……………..…………………………………………………………………..……………………….…..22
4.3. Connecting the DC input power cables…………………………………………………………………………………………..23
4.4. Connecting AC output power cables..……………………………………….….…………………….…………………………..27
4.5. Connecting the communication cables……………………...…………………………………………..………………………31
5. Commissioning the inverter………………………………………………………………………………………….………………........37
5.1. Safety inspection before commissioning………………………………………………………………………….…………….37
5.2. Starting the inverter……………………………………………………………………………………………………………………..37
6. Operating interface..…………………………………………………………………………………………………………………………..38
6.1. Operating panel and display………………………………………………………………………………….…………..………….38
6.2. Main interface………………………………………………………………..…………………..…………………………………..…….39
6.3. Main menu………………………………………………………………………………………………………….…………………….....41
7. Troubleshooting and maintenance………………………………………………………………………………………..………….....51
7.1. Troubleshooting…………………………………………………………………………………….…………………………………….51

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7.2. Maintenance..…………………………………………………………………………………………...…………………………………62
8. Uninstalling…………………………………………………………………………………….……………...………………………………….62
8.1. Steps for uninstalling the inverter…………………………………………………………………………………………………62
8.2. Packaging…………………………………………………………………………………………………………………………………….62
8.3. Storage…..………………………………………………………………………………………………………………….………………...62
8.4. Disposal…….………………………………………………………………………..……………………………………….………………62
9. Technical specifications.……………………………………………………………………………………………………………………..63
10. Warranty……………..………………………………………………………………………………………………………………..……………65

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General instructions
This manual contains important safety instructions that must be followed and during installation and
maintenance of the equipment.
Please keep these instructions!
This manual must be considered an integral part of the equipment and must always be available to everyone
who interacts with this equipment. The manual must always accompany the equipment, even when it is
transferred to another user or plant.
Copyright statement
The copyright of this manual belongs to Zucchetti Centro Sistemi S.p.A. No part of this manual may be copied
(including the software), reproduced or distributed in any form or by any means without the permission of
Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right to final interpretation. This manual
is subject to change based on feedback from users, installers or customers. Please check our website at
http://www.zcsazzurro.com for the latest version.
Zucchetti Centro Sistemi
Via Lungarno 305/A
52028, Terranuova Bracciolini (AR)
[phone]
[email protected]
http://www.zcscompany.com

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Preface
General information
Please read this manual carefully before installation, operation or maintenance.
This manual contains important safety instructions that must be followed during installation and
maintenance of the system.
Scope
This manual describes the assembly, installation, electrical connections, commissioning, maintenance and
troubleshooting of the following inverters:
3000TLM LITE / 3680TLM LITE / 4000TLM LITE / 4600TLM LITE / 5000TLM LITE / 6000TLM LITE
Keep this manual so that it is accessible at all times.
Recipients
This manual is intended for qualified technical personnel (installers, technicians, electricians, technical
support personnel or anyone who is qualified and certified to operate a photovoltaic system), who are
responsible for installing and starting up the inverter in the photovoltaic energy system and for operators of
the photovoltaic system.
Symbols used
This manual provides information for safe operation and uses certain symbols to ensure the safety of
personnel and materials, and for efficient use of the equipment during normal operation.
It is important to understand this information to avoid accidents and damage to property. Please take note
of the following symbols used in this manual.
Danger: indicates a hazardous situation which, if not resolved or
avoided, could result in serious injury or death.
Danger
Warning: indicates a hazardous situation which, if not resolved
or avoided, could result in serious injury or death.
Warning
Caution: indicates a hazardous situation which, if not resolved
or avoided, could result in minor or moderate injury.
Caution
Attention: indicates a potentially hazardous situation which, if
not resolved or avoided, could result in damage to the system, or
other property.
Attention
Note: provides important tips on the correct and optimal
operation of the product.
Note

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1. Preliminary safety instructions
If you have problems or questions regarding the reading and
understanding of the following information, please contact
Zucchetti Centro Sistemi S.p.A. through the appropriate
channels.
Note
General information in this chapter
Safety instructions
It mainly highlights the safety instructions to be followed during installation and use of the equipment.
Symbols and icons
Introduces the main safety symbols on the inverter.
1.1. Safety instructions
Before installing and using the equipment, make sure you read and understand the instructions in this
manual and familiarise yourself with the relative safety symbols shown in this chapter.
Depending on national and local requirements, permission must be obtained from your local provider before
connecting to the electrical grid, making sure that the connections are carried out by a qualified electrician.
Contact the nearest authorised service centre for any repairs or maintenance. Contact your distributor for
information on the nearest authorised service centre. DO NOT carry out repairs yourself, as this may result
in injury or damage.
Before installing and commissioning the equipment, interrupt its operation by turning off the DC switch to
disconnect the high voltage direct current of the photovoltaic system. The high voltage direct current can
also be interrupted by opening the switch of the photovoltaic panel. Failure to do so could result in serious
injury.
Qualified personnel
Ensure that the operator has the necessary skills and training to operate the equipment. Personnel
responsible for the use and maintenance of the equipment must be qualified and capable of performing the
activities described, and must also have appropriate knowledge on how to correctly interpret the contents of
this manual. For safety reasons, this inverter can only be installed by a qualified electrician with the
necessary training and/or skills and knowledge. Zucchetti Centro Sistemi S.p.A. declines all responsibility for
damage to property or personal injury caused by incorrect use or the device.
Installation requirements
Install and start the inverter according to the following instructions. Place the inverter on suitable load-
bearing supports with sufficient load capacity (such as walls or photovoltaic racks) and make sure that the
inverter is positioned vertically. Choose a suitable location for the installation of the electrical equipment.
Make sure there is sufficient space for heat dispersion and to accommodate future maintenance. Maintain
adequate ventilation and ensure that there is enough air circulation for cooling.

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Figure 1 –Do not lose or damage this manual
If you have problems with the packaging that could damage the inverter or if you find any visible damage,
immediately notify the transport company. If necessary, request assistance from an installer of photovoltaic
systems or from Zucchetti Centro Sistemi SpA. Transport of the equipment, especially by road, must be
carried out with vehicles suitable to protect the components (in particular, electronic components) against
violent knocks, humidity, vibrations, etc.
Electrical connections
Please pay attention to the electrical regulations on accident prevention when dealing with photovoltaic
inverters.
Before connecting the mains power, be sure to disconnect the
photovoltaic modules by disconnecting all the DC switches of the
generator. When exposed to the sun, the photovoltaic generator
produces a voltage that can be dangerous!
Danger
All installation operations must be carried out by a professional
electrician, who must:
be prepared.
carefully read this manual and understand its contents.
Warning
Before connecting the inverter to the grid, make sure that all the
necessary permits have been obtained from the local grid operator
and that all the electrical connections are made by a professional
electrician.
Attention
Do not remove the information label or open the inverter.
Otherwise, ZCS will not provide any warranty or maintenance.
Note

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Operation
Contact with the electrical grid or the terminal of the equipment may
cause electrocution or fire!
• Do not touch the terminal or the conductor connected to the electrical
grid.
• Follow all the instructions and safety requirements relating to the mains
connection.
Danger
Some internal components reach very high temperatures when
the inverter is in operation. Wear protective gloves!
Attention
Maintenance and repair
Before carrying out any repairs, disconnect the inverter from the mains
network (AC side) and from the photovoltaic system (DC side).
After switching off the AC and DC switches, wait 5 minutes before carrying
out any repairs or maintenance on the inverter!
Danger
The inverter should start working again after any faults have been fixed.
For any repairs, contact your local authorised service centre;
Do not disassemble the internal components of the inverter without
permission. This will void the warranty. Zucchetti Centro Sistemi S.p.A.
shall not be responsible for any damage or loss caused by these actions.
Attention

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1.2. Symbols and icons
Safety signals
Pay attention to possible burns due to hot parts.
Only touch the screen or press the keys while the inverter is in
operation.
Caution
The PV strings should be connected to the ground in accordance
with the local regulations.
•To ensure the safety of the system and people, the inverter
and photovoltaic strings must be securely connected to
the ground.
Attention
Ensure the correct DC input voltage; which must be below the
maximum allowable DC voltage. Overvoltage can cause
permanent damage to the inverter or other faults which are
not covered by the warranty!
Warning
Symbols on the inverter
Some safety symbols are located on the inverter. Read and understand the contents of the symbols before
installing the inverter.
Residual voltage may be present on the inverter! Before opening the
inverter, wait 5 minutes to ensure that the capacitors are completely
discharged.
Be careful of high voltage
Be careful of high temperatures
Complies with the European Standards (CE)
Grounding point

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Read this manual before installing the inverter.
Indication of the allowable temperature range
Degree of protection of the equipment according to the IEC 70-1
standard (EN 60529 June 1997).
Positive pole and negative pole of the input voltage (DC).
2. Product features
General information in this chapter
Product presentation
The field of use and overall dimensions of the 3K-6K TLM-L inverters are indicated in this section.
Description of functions
It describes how the 3K-6K TLM-L inverters and their internal operating modules work.
Efficiency curve
It describes the efficiency curves of the inverter.
2.1. Product presentation
Field of use
The 3K-6K TLM-L inverters are grid-connected photovoltaic inverters equipped with a dual-channel-MPPT,
capable of converting the direct current generated by the photovoltaic strings into three-phase sine wave
alternating current and feeding the energy to the public electricity grid. An AC circuit breaker (see chapter 4.4)
and DC circuit breaker must be used as disconnecting devices and must always be easily accessible.
Figure 2 –Grid-connected photovoltaic system

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The 3K-6K TLM inverters can only be used with photovoltaic modules that do not require one of the poles to
be grounded. The operating current and voltage during normal operation must not exceed the limits
indicated in the technical specifications. Only photovoltaic modules can be connected to the input of the
inverter (do not connect batteries or other power supply sources).
• Optional components of the inverter should be chosen by a qualified technician who is familiar with the
installation conditions.
• Overall dimensions: H x W x D = 478 mm x 344 mm x 170 mm
Figure 3 –Front, side and back view of the inverter and bracket

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Labels on the inverter
Figure 4 –Do not remove the label on the side of the inverter
2.2. Description of functions
The DC power generated by the PV modules is filtered through the input board before entering the power
board. The input board also has the function of detecting the insulation impedance and the DC input
voltage/current. The power board converts the DC power into AC power. The current converted into AC is
filtered through the output board and is then fed into the grid. The output board also has the function of
measuring the grid and GFCI voltage/current and acts as an output insulation relay. The control provides the
auxiliary power supply, controls the operating status of the inverter and shows it on the display. The display
also shows the error codes when the inverter is not functioning properly. At the same time, the control board
can activate the protection relay in order to disconnect the inverter from the grid.
Inverter functions
A. Feeding reactive power into the grid
The inverter is able to produce reactive power and feed it into the grid through the setting of the Power
Factor. The feed-in management can be controlled directly by the grid company through a dedicated RS485
interface.
B. Limiting the active power fed into the grid
If enabled, the inverter can limit the amount of active power fed into the grid at the desired value (expressed
as a percentage).
C. Automatic power reduction when grid is over frequency
When the grid frequency is higher than the limit set, the inverter reduces the output power in order to
ensure the stability of the grid.
D. Data transmission
The inverter (or a group of inverters) can be monitored remotely via an advanced communication system
based on a RS485 interface or via Wi-Fi.
E. Software update
A microSD card is used to update the firmware.

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Wiring diagram
Figure 5 –Block diagram of the 3K-6K TLM-L inverter
2.3. Efficiency curve
Efficiency curve for a Azzurro ZCS 5000 TLM-L model
Figure 6 –Efficiency curve for an Azzurro ZCS 5000 TLM-L inverter

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3. Installation
General information in this chapter
This chapter describes how to install the 3K-6K TLM-L inverter.
Installation notes:
DO NOT install 3K-6K TLM-L inverters near flammable materials.
DO NOT install 3K-6K TLM-L inverters in an area where flammable or explosive
materials are stored.
Danger
The housing and heat sink may become very hot while the inverter is running, DO NOT
install the inverter in places where they may be touched inadvertently.
Warning
Consider the weight of the inverter when handling and transporting the inverter.
Choose an appropriate mounting position and surface.
Assign at least two people to install the inverter.
Attention
3.1. Installation process
Figure 7 –Installation steps
3.2. Checks before installation
Checking the outer packaging
The packaging materials and components may be damaged during transportation. Therefore, please check
the materials of the outer packaging before installing the inverter. Check the surface of the box for external
damage such as holes or tears. If any kind of damage is found, do not open the box containing the inverter
and contact the supplier and transport company as soon as possible.
It is recommended to remove the packaged materials from the box 24 hours before installing the inverter.
Checking the product
After removing the inverter from its packaging, check that the product is intact and complete. If any damage
is found or components are missing, contact the supplier and transport company.
Contents of the packaging

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Carefully check the contents of the packaging before installation, making sure that no element inside the
packaging is missing or damaged.
The package will contain the following components:
1 Photovoltaic inverter
1 mounting bracket
2 + input terminals
2 - input terminals
2 Metal terminals for +
DC power cables
2 Metal terminals for - DC
power cables
2 M5 hexagonal screws
7 M6 flat washers
7 expansion plugs (2
spares)
5 self-tapping screws
1 user manual
1 warranty
1 certificate
1 AC output connector
1 Terminal 485 (2 pin)
1 Stopper A
1 Stopper B

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3.3. Installation tools
The following tools are required for installation of the inverter and electrical connections; therefore, they
must be prepared before installation.
No.
Tool
Function
1
Drill
Recommended drill bit: 6 mm
To drill holes in the wall for
fixing the bracket
2
Screwdriver
To screw and unscrew screws for
the various connections
3
Wire stripper
To prepare the cables for wiring
4
Adjustable spanner (opening
greater than 32 mm)
To tighten the bolts
5
4 mm Allen key
To screw the inverter to the wall-
mounting bracket and to open
the front cover of the inverter
6
RJ45 crimping tool
To crimp the RJ45 connectors for
the communication cables
7
Rubber hammer
To insert the expansion plugs
into the wall holes
8
MC4 removal tool
To remove the DC connectors
from the inverter
9
Diagonal pliers
To cut and tighten the cable ends

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10
Wire stripping tool
To remove the outer sheath of
the cables
11
Cable cutter
To cut the power cables
12
Crimping tool
To crimp the power cables
13
Multi-meter
To check the voltage and current
values
14
Marking pen
To mark the wall for better fixing
precision
15
Measuring tape
To measure distances
16
Level
To make sure the bracket is level
17
ESD gloves
Protective clothing
18
Safety goggles
Protective clothing
19
Protection mask
Protective clothing

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3.4. Installation position
Choose an appropriate installation location for the inverter.
Follow the requirements below to determine the installation position.
Figure 8 –Requirements for installing a single inverter

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Figure 9 –Requirements for installing multiple inverters
For safety reasons, ZCS Spa and/or its partners may not carry out any technical repairs or maintenance
work, or move the inverter from and to the ground if it is installed at a height of more than 180 cm from the
ground.
Inverters installed at higher heights must be moved to the ground before they can be repaired or serviced.
3.5. Moving the 3K-6K TLM-L inverter
This section describes how to move the inverter correctly
1) When opening the packaging, insert your hands into the slots on both sides of the inverter and take a
hold of it as shown in Figures 10 and 11.
Figure 10 –Removing the polystyrene protections

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Figure 11 –Removing the inverter from its packaging
2) Lift the inverter from its packing box and move it to the installation position, then remove the
polystyrene protections.
To prevent damage and personal injury, hold the inverter firmly when moving, as
it is a heavy piece of equipment.
Do not position the inverter with the input/output terminals in contact with other
surfaces, as these are not designed to support the weight of the inverter. Always
position the inverter horizontally.
When placing the inverter on the floor, make sure to place a support under the
unit to protect its front door.
Attention
3.6. Installing the 3K-6K TLM-L inverter
1) Correctly position the mounting bracket on the wall using a level to ensure that it is straight; mark the
five holes using a suitable marker pen. Keeping the hammer drill perpendicular to the wall and avoiding
any sudden movements when drilling, drill the five holes at the points marked on the wall using a 6 mm
drill bit. In case of errors during drilling, it is necessary to reposition the holes.
2) Insert the plugs horizontally into the holes made, paying attention to the force and depth with which
they are inserted (make sure the plug completely enters the hole).
3) Align the mounting bracket with the position of the holes and fix it to the wall using the screws and flat
washers supplied, tightening them properly.
4) Place the inverter on the mounting bracket
5) Secure the inverter to the mounting bracket with the M5 bolt to ensure stability.
6) (OPTIONAL) Depending on the customer’s requirements, the inverter can be locked to the mounting
bracket with a safety lock (not supplied with the kit).