Zeversolar Zeverlution Series Manual

STANDARD OPERATING PROCEDURE
String Inverter Installation – Zeverlution Series
Version 1.2 Effective date 02/08/2017
Page 1 of 15
SOP Title:
String Inverter Installation – Zeverlution Series
Version:
SOP1103-PV-v1.2
Effective Date: 02/08/2017
DOCUMENT CONTROL
Version no. Date Significant Changes Author Reviewer
1.0 08/05/17 Draft Timm Brehm TH, AF, ME, KW
1.1 03/07/17 Issued Timm Brehm TH, AF, ME, KW
1.2 02/08/17 Monitoring setup revised T Heine TB
Table of Contents
PURPOSE .....................................................................................................................................2
SCOPE..........................................................................................................................................2
SYMBOLS USED IN THIS DOCUMENT ............................................................................................2
GENERAL GUIDELINES ..................................................................................................................2
BEHAVIOURAL.................................................................................................................................. 2
SAFETY............................................................................................................................................. 2
INSTALLATION PROCEDURE .........................................................................................................3
String Design Guidelines ................................................................................................................... 3
5.1.1 String Layout Without Optimisers .......................................................................................................3
5.1.2 String Layout with Optimisers..............................................................................................................3
5.1.3 Shading.................................................................................................................................................3
5.1.4 Maximum String Voltage......................................................................................................................4
String Inverter Installation................................................................................................................ 4
5.2.1 Zeversolar Zeverlution 2000s...............................................................................................................4
5.2.2 Zeversolar Zeverlution 4000 ................................................................................................................4
5.2.3 Wall Mounting .....................................................................................................................................5
Wiring.............................................................................................................................................. 6
5.3.1 DC Wiring .............................................................................................................................................6
5.3.2 TS4-R-O Optimiser installation.............................................................................................................9
5.3.3 AC Wiring ...........................................................................................................................................10
SYSTEM COMMISSIONING .........................................................................................................11
Commissioning Tests ...................................................................................................................... 11
Grid Protection Settings ................................................................................................................. 11
6.2.1 Adjusting grid protection settings using the inverter display ............................................................11
Connecting the inverter to the Internet........................................................................................... 12
6.3.1 Connecting the inverter to the internet using WIFI...........................................................................13
6.3.2 Connecting the inverter to the internet using Ethernet....................................................................15

STANDARD OPERATING PROCEDURE
String Inverter Installation – Zeverlution Series
Version 1.2 Effective date 02/08/2017
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PURPOSE
This document provides all solarcity installation partners and employees with guidelines and instructions
for the installation of single and dual MPPT inverters for residential solarZero and solarClassic systems.
SCOPE
This document applies to single-phase installations with Zeversolar string inverters and covers the
mechanical and electrical part of the inverter installation instruction. The focus of this SOP lies on the
physical installation of Zeverlution 2000s and Zeverlution 4000 inverters and any associated switch gear,
DC and AC wiring.
SYMBOLS USED IN THIS DOCUMENT
Danger: destruction of property, serious injury or death may occur
Warning: Damage to equipment/ property or minor injury may occur
Note: for informational purposes
Reference to other section in this document, or an external document.
GENERAL GUIDELINES
BEHAVIOURAL
Always follow solarcity’s
Code of Conduct while on site.
SAFETY
Follow NZ Healt
h & Safety laws and regulations, your company’s and/or solarcity’s Health & Safety
Policy
.

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Version 1.2 Effective date 02/08/2017
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INSTALLATION PROCEDURE
String Design Guidelines
To ensure efficient operation and compliance with the regulations, string design options are
limited. As per AS/NZS 5033 section 2.1.6, PV modules that are in the same string must have the
same tilt and azimuth angle within a tolerance of ±5°.
solarcity w
ill determine which layout is most suitable based on a site visit prior to the installation. If
you find the provided layout to be unsuitable on the day of installation, please contact solarcity
immediately. The below section should provide a better unders
tanding of our design guidelines.
As a solarcity installer or contractor, you are expected to report any possible discrepancies with
the below design guidelines immediately before you proceed with your work.
For both the Zeverlution 2000s and the Z
everlution 4000 inverters and for arrays with or without
opt
imisers the minimum and maximum strings lengths are as follows:
-minimum number of modules per string is 3
-maximum number of modules per string is 10
5.1.1 String Layout Without Optimisers
Where no optimisers are deployed, modules that are electrically connected as one string need to
be in the same orientation and tilt.
5.1.2 String Layout with Optimisers
The deployment of Tigo TS4-R-O optimisers allows modules in a single string to be installed as
split-arrays with different azimuth and/or tilt angles. As a general guideline, the main or most north
facing array must have a minimum of 3 modules to reach the inverters start up voltage and won’t
be optimized – while the “sub-array” will be optimized. Examples of array configurations and the
correct deployment of optimisers are shown below (with optimized modules shown in blue).
5.1.3 Shading
The benefit of optimisers in partially shaded arrays is insignificant. For solarZero systems, in some
instances
, shading is mitigated by installing one additional module. solarcity will determine if this
is a suitable so
lution on a case by case basis.

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5.1.4 Maximum String Voltage
The maximum length of a single string is dictated by the string voltage, taking temperature
coefficients and the local ambient temperatures into account. For all solarcity installation zones,
the maximum number of panels in a single string of 60-cell modules with a rated output at STC of
less than or equal to 300 Watts, is ten (10). The string length is also limited by the DC isolator’s
rating.
String Inverter Installation
The following section describes the physical installation of the string inverter for solarZero and
solarClassic systems. The range of string inverters is currently limited to two models, a 2kW and a
4kW unit.
5.2.1 Zeversolar Zeverlution 2000s
This inverter is used for systems with a peak output between 1.5kWp and 3kWp (6 to 10 modules),
where the peak performance rating per panel at STC does not exceed 295Wp.
For further details please refer to the
Zeverlution 2000s datasheet.
DC Input
The inverter is equipped with a single MPPT input. The single string is connected using
SUNCLIX
connectors
of which one pair is supplied with the inverter.
Model Zeverlution 2000s
Convertible power 2350W
Max input voltage 500V
MPP voltage range 70V - 450V
Min DC start voltage 80V
Max DC input current 11A
AC Output
The inverter has an AC screw terminal block for connecting the AC cabling.
Model Zeverlution 2000s
Rated active power 2000W
Max apparent power 2200VA
Rated grid voltage 230V
Max AC output current 10A
Min MCB rating 16A (type C)
5.2.2 Zeversolar Zeverlution 4000
The Zeverlution 4000 inverter is used for systems with a peak output between 3.4kWp and 6kWp.
For further details please refer to the
Zeverlution 4000 datasheet.
DC Input
The inverter has 2 individual MPPT inputs and comes with 2 pairs of SUNCLIX connectors.

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Model Zeverlution 4000
Convertible power 4650W
Max input voltage 600V
MPP voltage range 100V - 520V
Min DC start voltage 80V
Max DC input current 11A / 11A
AC Output
The inverter has an AC screw terminal block for connecting the AC cabling.
Model
Zeverlution 4000
Rated active power 4000W
Max apparent power 4400VA
Rated grid voltage 230V
Max AC output current 20A
Min MCB rating 25A (type C)
5.2.3 Wall Mounting
Mounting procedure
The inverters come with a mounting bracket, which is used to fix the units to a suitable wall.
Please refer to the solarcity wall cladding guide for suitable wall claddings to mount the inverter
on.
1. Use the wall bracket as a drilling template and
mark the positions of the drill holes. Ensure the
bracket is levelled before drilling. If the
supplied anchors and screws are used, drill 2
holes with a diameter of 10mm to a depth of
70mm. Place the anchors in the wall and
secure the bracket with the supplied hex-head
screws.
2. Once the bracket is securely mounted to the
wall, attach the inverter onto the bracket.
Check both sides of the heatsink to ensure the
inverter is positioned correctly.
3. Push the inverter towards the wall as far as
possible and secure it on both sides of the wall
bracket using the provided M5 screws (torque
2.2 Nm).

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Version 1.2 Effective date 02/08/2017
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Clearances
Heat must be able to dissipate from the inverter through the heatsink on the back. It is important
to consider the recommended clearances. The below
table is for a single inverter only.
Multiple inverters should only be installed side by side horizontally and never vertically stacked
one above the other.
Suitable locations
Suitable locations are the south, southeast and southwest facing walls of a building or the garage.
Porches that offer sufficient shelter can also be suitable. The inverter must not be installed in a
location, where it is exposed to direct
sunlight.
Wiring
5.3.1 DC Wiring
All wiring must be installed and sized in
accordance with the relevant requirements of AS/NZS
3000, AS/NZS 3008.1, AS/NZS 5033 and AS/NZS 4777.1.
All DC cabling and the associated earth bonding conductors should be bundled together to avoid
induction loops. Where possible, use the so-called “leapfrog wiring” method to avoid unnecessary
cable loops and home runs.
Source: http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg
If the leapfrog or skip wiring method is impractical, the modules can be daisy chained.
Source: http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg
Direction Minimum Clearance
above 300 mm
below 500 mm
sides 400 mm

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Any DC cabling must be adequately mechanically protected and must be run in HD Solar conduit.
Where it is exposed to direct sunlight, HD conduit, marked with the letter T, is to be used. For any
internal cable runs (e.g. within wall cavities, under floors
and within roof spaces), rigid HD solar
conduit shall be used. The conduit must be
labelled with PV or SOLAR at intervals not exceeding
2 meters. Refer to section 4.3 of AS/NZS 4777.1:2016. Use stainless steel saddles for all external
conduit runs.
Wiring between the inverter and the DC isolator may be without conduit where the length of DC
cable does not exceed 300mm.
The minimum cross section of any DC wiring is 4mm². All DC cables shall be multi-stranded,
insulated and sheathed and PV1-F rated as per AS5033. The table below shows the maximum
cable length (one way) between array and inverter with JA 290W panels, allowing for a 2% voltage
drop.
Panels per string 3 4 5 6 7 8 9 10
Max. cable length 25 25 25 30 35 40 45 50
Genuine MC4 connectors must be used to connect the DC cables to the array output cable. A
MC4 crimping tool is required to attach the stranded wire to the metal pin.
DC isolators
DC isolators must be installed adjacent to the inverter. The clearances for the inverter provided in
section 5.2.4 do not apply for any disconnection equipment. This means isolators can be installed
directly underneath or next to the inverter.
Solarcity supplies a Kraus & Naimer DC isolator - KFD25 T204/NZ-P002 KL11V. It is important that
the screw terminals of the DC isolator are not over tightened. A torque screwdriver shall be used
to tighten the terminal screws with a torque of 1.25Nm.
Remove the isolator from the enclosure prior to fixing the enclosure to the wall. Dust from drilling
can damage the switch.
Please see the
isolator datasheet for further details.

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SUNCLIX Connectors
The inverter uses SMA’s SUNCLIX to connect the DC string to the inverter. One (Zeverlution
2000s), or two pairs (Zeverlution 4000) respectively, are shipped with the inverter. It is important
to assemble the connectors correctly. Please take extra care not to damage these connectors in
the process. Be sure to maintain the correct polarity – the connectors are also marked with “+”
and “-“ symbols.
The steps below explain how to assemble SUNCLIX connectors. Ensure that the array cable is de
-
energized
before installing the connectors.
1. Strip approx. 12mm off the cable insulation
2. Route the cable all the way into the DC
connector. Ensure that the stripped cable and
the DC connector have the same polarity
3. If the stranded wires are visible in the chamber of the clamping bracket, the cable is positioned
correctly. Press the clamping bracket down until it snaps into place. You should hear a click.
4. Push the swivel nut up to the thread and tighten it (torque: 2Nm).

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5. If the connector’s clamping bracket was locked
prematurely (refer to step 3), it can be opened
using a 3.5mm flat bladed screw driver
Equipotential Bonding
Equipotential bonding is required for all parts of the solar array. The cross section of each earth
conductor should be equal or greater than that of the DC cable conductor size. The earth cable
must be continuous from the array to the earth bar in the switchboard the inverter is connected to.
Run all conductors bundled in the
same conduit.
solarcity policy is that the earth conductor must be bonded to every rail in each row or column of
the array using the supplied proprietary earth lugs.
Roof Penetration
Subject to the roof type the PV array is installed on, an appropriate roof penetration kit must be
used. Roof penetrations must always be located under the solar panels where an attic space is
accessible for the cable run.
Where cable(s) pass through the roof penetration, it must be protected using rigid conduit.
Rooftop Isolator
A rooftop isolator is not required. Refer to section 4.4.1.6 of AS/NZS 5033:2014 for details. The
output cabling of the array must be labelled as follows:
“The inverter DC isolator must be in ‘Off’ position before isolating the PV array”
5.3.2 TS4-R-O Optimiser installation
Where strings are split across two roofs with different orientations or roofs with different pitch,
optimiser
s must be partially deployed in the string (see 5.1.2). solarcity will specify the design and
optimiser deployment prior to the installation. Follow the below instructions to retrofit
optimisers
to the module.
1. Looking at the back of the panel, push
the optimisers into the upper right
corner at the backside of the module
frame as depicted. Make sure the unit is
pushed all the way in.

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2. Connect the module leads to the short
input leads of the TS4-R-O unit.
3. Connected the long output leads of the optimiser to the output leads of the next optimiser.
Secure any wiring loops and loose cables to the module frame or the mounting rails. All optimisers
come with genuine MC4s and so do the modules. If you find non-genuine connectors on either the
module or the optimisers, please contact solarcity immediately. The optimiser’s output leads have
a length of 1000mm which is usually too short for leapfrog wiring. Please use standard daisy chain
wiring for all optimised array sections.
5.3.3 AC Wiring
The inverter is connected to the switchboard using double insulated 3-core cable (2C+E). Circular
TPS should be used to connect the inverter to the AC isolator. Standard TPS cable can be used
for the cable run between switchboard and AC isolator. If no AC
isolator is required, use circular
TPS all the way from the inverter to the switchboard. External AC cabling must be run in UV
resistant HD conduit
(with the Solar T labelling hidden since it is AC not DC).
The table below shows the conductor cross section and maximum cable length for each inverter.
2.5mm² 4mm² 6mm²
Zeverlution 2000s 15m 25m 40m
Zeverlution 4000 n/a 15m 20m
max. cable length
conductor cross-section

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An AC isolator must be installed adjacent to the inverter if the inverter is more than 3 meters away
from the switchboard or it is out of line of sight. The AC isolator must have a current rating equal to
or greater than the MCB current rating.
MCB’s must be sized correctly according to the cable cross section used to connect the inverter
to the switch board. Please refer to the inverter datasheet or section
s 5.2.1 and 5.2.2 to determine
the appropriate MCB rating.
SYSTEM COMMISSIONING
Commissioning Tests
It is extremely important that all mandatory tests are done before commissioning the PV system.
Please make yourself familiar with Appendix D of AS/NZS 5033:2014 and follow the instructions
outlined in the standard.
Attached to this document you’ll
find a commissioning sheet which you may use to record the test
results. A completed and signed copy of the commissioning sheet together with the CCSC must
be provided to solarcity.
Grid Protection Settings
AS4777.2:2015 defines specific grid protection requirements for New Zealand. Before
commissioning the PV system, you must ensure that the inverter is set to the correct standard.
6.2.1 Adjusting grid protection settings using the inverter display
To change these settings, the inverter must be powered by DC only.
Keep in mind that the inverters need a minimum DC input power of 30Watts from the array to start
up. If the irradiance is insufficient in the late evening, you might not be able to access the inverters
settings menu.
1. With the AC isolator turned off, turn on the DC
isolator(s) and wait for the inverter to start. This
may take a few seconds. The display will show an
error code.

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2. Once the inverter has started, use the grey button
next to the display to change the information
shown on the display until the inverter name is
displayed, e.g. Zeverlution 4000 or Zeverlution
2000s.
3. When the inverter name is displayed, push and
hold down the button for 10 seconds. You will be
asked to enter a password.
4. The password is 25. The 3-digit number will
count-up by one each time you press the button.
Push the button repeatedly until the number 024
is displayed. Now push the button one more time
but hold it down for 10 seconds. The inverter is
most likely set to Australian settings by default.
5. Now press the button again once per second until
the display shows the correct standard -NZ
AS/NZS4777.2. To confirm, wait for approximately
10 seconds until the inverter automatically returns
to the initial display, showing the error code.
Connecting the inverter to the Internet
The inverter needs to be connected to the customer’s internet connection so that it can be monitored for
performance and maintenance (e.g. earth faults). This can be done via WIFI or Ethernet. The order of
preference for internet connection is as follows:
1. If there is WIFI signal at the inverter location, connect via WIFI – refer to section 6.3.1 for
connecting the inverter using WIFI
2. If there is no WIFI signal at the inverter location, use a TPLink WIFI extender to extend the WIFI
signal to the inverter location – refer to section 6.3.1 for connecting the inverter using WIFI
3. If WIFI cannot be extended to the inverter location, use an Ethernet bridge to connect the inverter
directly to the customer’s router. This example may arise if the inverter is installed in a garage
away from the main house. Where the cable run is relatively short, it is preferable to run an

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Ethernet cable directly to the router. Refer to Section 6.3.2 for connecting the inverter using
Ethernet.
6.3.1 Connecting the inverter to the internet using WIFI
1. Install the supplied WIFI antenna to the
bottom of the inverter before setting up
the WIFI connection.
2. With the
inverter powered up, use a
smartphone or laptop to search for the
inverter’s wireless access point. This
will display as ZEVERSOLAR-XXXX.
Connect to this using the password
‘zeversolar’.
3. Open a new browser window and
enter http://160.190.0.1 in the address
bar to access the inverter settings
interface.
4. If the address cannot be loaded, press
the button on the inverter display to
cycle through the menu until an IP
address is displayed. If this isn’t
160.190.0.1 use the IP address shown
on the inverter’s display .

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5. Select the wireless menu and connect
to the customer’s wireless network.
6. After approximately one minute the
inverter should connect to the
customers wifi network and the status
indicator on the wireless page will
show a green tick.
7. Take a photo of the serial number and
reg. key of the inverter. The label is
usually placed on the right side of the
inverter. Upload this photo to google
drive as part of the installation photos.

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6.3.2 Connecting the inverter to the internet using Ethernet
To use this method the customers router must have DHCP enabled.
1. Connect the Ethernet port on the
inverter to the Ethernet
port on the
customers router directly via and
Ethernet cable or Ethernet bridge. The
Ethernet port in the inverter is labelled
‘ETH’.
2.
Run the Ethernet cable through the
comms gland on the bottom of the
inverter ensuring that the cable entry is
sealed from dust and moisture.
3. The inverter automatically obtains an IP address from the router via DHCP and connects to the
internet. This process may take a minute or two.
4. Press the button on the inverter display
to cycle through the menu until an IP
address is displayed. If the inverter is
connected to the internet ‘Connected’
should show beneath the IP address.
5. Take a photo of the serial number and
reg. key of the inverter. The label is
usually placed on the right side of the
inverter. Upload this photo to google
drive as part of the installation photos.

Commissioning Test Sheet
Residential - String Inverter
CTS1039-PV-v4
Page 1 of 1
solarcity PV array commissioning sheet
Address of installation
COC Reference/Certificate ID Number
Date of Testing
Number of PV modules in string 1
Number of PV modules in string 2 (if applicable)
Number of DC optimisers (if used)
Continuity
Earth continuity 1 – Earth busbar to earth rod (MEN link removed) Ω
Earth continuity 2 – Main earth conductor to array frame Ω
Polarity check and PV open circuit voltage
Polarity
Voltage (V)
String 1
String 2 (if applicable)
PV array at switch disconnector
Insulation resistance measurements
Array positive to earth MΩ
Array negative to earth MΩ
System Operation
PV operating voltage V
PV operating current – string 1 A
PV operating current – string 2 (if applicable) A
PV array switch-disconnector operating correctly under load YES / NO
Time of day
Sunlight/irradiance at time of testing SUNNY / CLOUDY – BRIGHT / CLOUDY - DARK