ZCS HYDxxxxES Series User manual

HYD 3000/3600/4000/5000/6000-ES
User Manual
2018-10-19
Version V1.1

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CONTENT
1. HYD-ES inverter Introduction.......................................................................................................................................3
2. Safety Notes.................................................................................................................................................................4
2.1. Safety Notes......................................................................................................................................................4
2.2. Installation and Maintenance Notes.................................................................................................................4
2.3. Signs on the inverter.........................................................................................................................................5
3. Installation...................................................................................................................................................................7
3.1. Product Overview.............................................................................................................................................7
3.2. Packing List .......................................................................................................................................................8
3.3. Installation Environment ..................................................................................................................................8
3.4. Installation Tools...............................................................................................................................................9
3.5. Installation Position ........................................................................................................................................10
3.6. Mount HYD-ES inverter...................................................................................................................................11
4. Electrical Connection.................................................................................................................................................12
4.1. Battery Connection.........................................................................................................................................13
4.2. PV Connection ................................................................................................................................................13
4.3. CT / CAN / RS485 / NTC connection ...............................................................................................................15
4.4. Grid Connection..............................................................................................................................................17
4.5. Critical Load Connection (EPS function) .........................................................................................................18
5. Buttons and indicator lights.......................................................................................................................................19
5.1. Buttons: ..........................................................................................................................................................20
5.2. Indicator lights and status of HYD-ES inverter................................................................................................20
6. Operation...................................................................................................................................................................21
6.1. Double Check..................................................................................................................................................21
6.2. First Time Setup (IMPORTANT!)......................................................................................................................21
6.3. Commissioning ...............................................................................................................................................23
6.4. Menu ..............................................................................................................................................................24
6.4.1. Basic setting:........................................................................................................................................25
6.4.2. Advanced setting: ................................................................................................................................32
6.4.3. Event List..............................................................................................................................................36
6.4.4. System information interface ..............................................................................................................36
6.4.5. Energy Statistic：................................................................................................................................37
6.4.6. Software upgrade ................................................................................................................................38
7. Technical Data............................................................................................................................................................39
8. Troubleshooting.........................................................................................................................................................41

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

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

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

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

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

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

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Maximum altitude: 2000m
3.4. Installation Tools
The following tools shall be prepared before installation:
No.
Tool
Model
Function
1
Hammer drill
Recommend drill dia.6mm
Used to drill holes on the wall
2
Screwdriver
wiring
3
Wire stripper
Strip wire
4
4mm Allen Key
Turn the screw to connect rear panel
with inverter
5
Crimping tools
Used to crimp power cables
6
Multi-meter
Used to check grounding
7
Marker pen
Used to mark signs
8
Measuring tape
Used to measure distances
9
Level
Used to ensure that the rear panel is
properly installed
10
ESD gloves
Operators wear

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11
Safety glasses
Operators wear
12
Anti-dust respirator
Operators wear
3.5. Installation Position
HYD-ES inverter should be vertically mounted (to ensure good heat dissipation), please choose a position without
direct sunlight and/or snow accumulation to install HYD-ES inverter. Ensure that the installation position is well-
ventilated.
OK
NO
Fig. 4 Installation Position of HYD-ES inverter

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3.6. Mount HYD-ES inverter
Step 1: Put the mounting bracket properly on the wall, mark these 8 drill holes using a marker pen. Drill 8 holes (drill
bit 6mm) on the wall.
Step 2: Insert the expansion screw vertically into the hole, note the insertion depth. (not too shallow or too deep)
Step 3: Fix the mounting bracket on the wall using bolts & flat washers.
Step 4: Put HYD-ES inverter on the mounting bracket.
Step 5: Connect HYD-ES inverter to PE using the grounding hole on the heat sink.
Step 6: OPTIONAL: you can lock HYD-ES inverter to the mounting bracket.
Step 5 Step 6

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

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

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

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4.3. CT / CAN / RS485 / NTC connection (for Pylontech battery)
The CT (Current transformer) measures the value and direction of AC current. Refer to Fig. 11 for the correct
connection of CTa.
Fig. 11 CTa connection
Step 1: Refer to Fig. 11 for correct position of CTa. Install the CT around the L wire of incoming power line.
Step 2: You can use network cable & terminal caps to extend CT wires if necessary, the maximum CT cable length is
200m.
CT wire
Extension cable (network cable)
HYD-ES inverter
Red
Orange / white orange / brown / white brown
CT+
Black
Green / white green / blue / white blue
CT-

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

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Fig. 13 NTC connection
Step 7: fasten the waterproof cover using 4 screws.
If battery different than Pylontech are used contact ZCS technical support.
4.4. Grid Connection
Step 1: Loosen 4 screws (part A) using a screwdriver (fig. 14)
Step 2: Remove the waterproof cover (part B), loosen the cable gland (part C), then remove the stopper (part G)
Step 3: Route a 3-wire power cable through GRID cable gland, then connect the 3 wires to the corresponding
terminal blocks. (BROWN –L, BLUE –N, YELLOW/GREEN –PE)
Step 4: Fasten the waterproof cover using 4 screws.
Fig. 14 Grid & Load connection

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4.5. Critical Load Connection (EPS function)
Critical load: in case of power outage, if EPS function is enabled, HYD-ES inverter will work in EPS (Emergency Power
Supply) mode, utilize the PV power & energy stored in the battery to supply power to critical load via the LOAD
connection output.
LOAD connection output is only for critical load connection. The combined power of critical loads must be less than
3000VA.
The connection procedure of the LOAD Output is the same as the grid output connection (Fig. 14).
Transfer switch positions: refer to Fig 15
CAUTION
A transfer switch is necessary.
While checking/repairing critical load, make sure transfer switch switch is at
position 0 that disconnect the critical load both from the grid and from the HYD-ES
Inverter.
While checking/repairing HYD-ES inverter, make sure the transfer switch is at
position 0 and the HYD-ES inverter is disconnected from grid.
Under normal conditions: Transfer switch is at position 2. The Grid will supply power to critical load.
In case of black out , change the switch to position 1. the HYD-ES inverter will provide power to critical load.
If the HYD-ES inverter is faulty, change the switch to position 2. Grid will supply power to critical load.

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Fig. 15 Change-over Switch connections
5. Buttons and indicator lights

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