ZUCCHETTI 1.1K-3K TL, User Manual

Page 1: ...81 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 39 055 91971 fax 39 055 9197515 innovation zcscompany com zcs pec it www zcsazzurro com Grid connected inverter 1 1K 3K TL User Manual V2 1 07 06 2019 ...

Page 2: ...n 14 3 3 Installation tools 16 3 4 Installation position 18 3 5 Moving the ZCS 1 1 3K TL inverter 19 3 6 Installing the ZCS 1 1 3K TL inverter 20 4 Electrical connections 21 4 1 Electrical connections 22 4 2 Ground cable connections PNGD 22 4 3 Connecting the DC input power cable 24 4 4 Connecting the AC output power cables 27 4 5 Connecting the communication cables 30 4 6 Communication systems 33...

Page 3: ... 07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL 7 Troubleshooting and maintenance 54 7 1 Troubleshooting 54 7 2 Maintenance 59 8 Uninstalling 59 8 1 Steps for uninstalling the inverter 59 8 2 Packaging 59 8 3 Storage 59 8 4 Disposal 59 9 Technical specifications 60 10 Warranty 62 ...

Page 4: ...uipment 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 manua...

Page 5: ...g 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 n...

Page 6: ... distributor for information on the nearest authorised service centre DO NOT carry out repairs yourself as this may result in injury or damage 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 skilled and capable of performing the activities described and must also h...

Page 7: ...nts against violent knocks humidity vibrations etc Electrical connections Please comply with all the electrical regulations on the prevention of accidents related to 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 c...

Page 8: ...omponents 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 sh...

Page 9: ... strings must be securely connected to the ground Attention Ensure the correct DC input voltage this must be below the maximum allowable DC voltage Overvoltage can cause permanent damage to the inverter that is 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 Re...

Page 10: ...the 1 1K 3K TL inverters are indicated in this section Function description It describes how the 1 1K 3K TL 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 1 1K 3K TL inverters are grid connected photovoltaic inverters equipped with a single MPPT channel capable of converting the direc...

Page 11: ...t current and voltage of the PV strings must not exceed the limits specified 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 Accessories and optional components of the inverter should be chosen by a qualified technician who is familiar with the installation conditions Overall dimensions L...

Page 12: ...e 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 and protect the internal components 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 ma...

Page 13: ...tion GID Manual of 07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL Wiring diagram Figure 5 Block diagram of the 1 1K 3K TL inverter 2 3 Efficiency curve Efficiency curve for a Azzurro ZCS 3000 TL model Figure 1 Efficiency curve for an Azzurro ZCS 3000 TL inverter ...

Page 14: ...se an appropriate mounting position and surface 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...

Page 15: ...king sure that no element inside the packaging is missing or damaged The package will contain the following components 1 Photovoltaic inverter 1 mounting bracket 1 input terminal 1 input terminal 1 Metal terminal for DC power cables 1 Metal terminal for DC power cables 2 M5 hexagonal screws 10 M6 flat washers 7 expansion plugs 2 spares 5 self tapping screws 1 user manual 1 warranty 1 certificate 1...

Page 16: ...ng the bracket 2 Screwdriver To screw and unscrew screws for the various connections 3 Wire stripping tool 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 ...

Page 17: ... 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 the 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 ...

Page 18: ...D Manual of 07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL 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 ...

Page 19: ... 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 1 1K 3K TL inverter This section describes how to move the inverter correctly 1 Open the packaging and remove the protective cover in polystyrene insert your hands into the slots on both sides ...

Page 20: ... 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 pl...

Page 21: ...nections ensure that the DC circuit breaker is switched off Please note that the capacitors in the inverter may remain electrically charged after the DC circuit breaker has been switched off Therefore it is necessary to wait at least 5 minutes to allow the capacitor to discharge completely The inverter must be installed and serviced by professional technicians or electricians Attention The PV modu...

Page 22: ...onnect the 1 1K 3K TL inverter to the ground electrode using ground protection cables PGND The inverter does not have a transformer therefore the positive pole and negative pole of the photovoltaic string does NOT need to be grounded Otherwise the inverter may fail All non current carrying metal parts such as the PV module frame PV rack housing of the combiner box and housing of the inverter in th...

Page 23: ...art L4 is the distance between the crimped part and the conductor wires protruding from the crimped part Note 2 The cavity formed after the conductor has been crimp must completely wrap the conductor wires The core of the wire must be in close contact with the terminal Figure 15 Preparing the ground cable 2 3 Install the crimped OT terminal and flat washer using the M5 screw in the hole located on...

Page 24: ...n circuit voltage for each string must be less than 1000 VDC The output power for each PV string must be less than or equal to the maximum input power allowable for 1 1K 3K TL inverters The positive and negative terminals of the PV strings must be connected respectively to the positive and negative inputs of the input terminal block Attention Before connecting the power supply be sure to disconnec...

Page 25: ...th the positive and negative connectors respectively Separate the positive and negative metal terminals after unpacking the inverter so as to avoid confusing the polarities Procedure 1 Remove the cable glands from the positive and negative connectors 2 Remove an appropriate length of the insulation layer from the positive and negative power cables by using a wire stripper as shown in the figure Fi...

Page 26: ...the corresponding seats until you hear a click sound At that point the power cables will be snapped into place 6 Replace the cable glands on the positive and negative connectors and rotate them against the insulation covers 7 Insert the positive and negative connectors into the corresponding DC input terminals of the inverter until you hear a click sound as shown in the figure Figure 20 Connecting...

Page 27: ...n device should always be operational and ready to operate Warning Context The AC power cables used for the inverter must be three pole outdoor cables For easier installation use flexible cables The table lists the recommended specifications for cables and circuit breakers Type 1100TL 1600TL 2200TL 2700TL 3000TL Cable mm2 4 4 4 4 4 Switch 16A 400V 16A 400V 25A 400V 25A 400V 25A 400V Table 2 Recomm...

Page 28: ...n the cable is less than 1 of the rated power and to ensure proper functioning of the anti islanding protection The cable length from the inverter to the grid should not exceed 150 meters The figure below shows the relationship between the power loss in the cable its length and the cross section area Figure 25 Relationship between power loss length and cable cross section The 1 1K 3K TL inverters ...

Page 29: ...isassemble the AC connector as shown in the figure below insert the AC output cable with its stripped insulation layers as shown in step 1 through the PG waterproof cable gland Figure 28 Connecting the AC output cables 2 3 Connect the AC power cable according to the following criteria Connect the ground wire yellow green to the terminal labelled PE and tighten the cable with an Allen key Connect t...

Page 30: ...ng device reaches its intended position as shown below Figure 30 Connecting the AC output cables 4 4 5 Connecting the communication cables Connecting the communication port Note The wiring procedure is the same for the RS485 input I O input and CT input This chapter describes the steps to be followed for connecting the communication cables Communication port RS485 I O CT Cable cross section 0 5 1 ...

Page 31: ...the cable glands and stoppers Note The waterproof connectors refer respectively to from left to right RS485 Input Output CT Remove the waterproof connectors according to the communication functions to be used DO NOT remove the unused connectors 3 Choose a suitable cable according to Table 4 2 and remove the outer insulation part using a cable stripping tool insert the cable through the cable gland...

Page 32: ... 4 4 connect the cables as shown in the labels and secure them using a flat screwdriver Note keep the unused terminals for future use Type RS485 I O CT Connector Label TX TX 5V GND I4 I3 I2 I1 CT CT Function RS485 differential signal RS485 differential signal Source Ground Input 4 Input 3 Input 2 Input 1 CT CT Table 4 Description of the communication terminals and their function Figure 34 Tighteni...

Page 33: ...bles TX in parallel then connect the two 485 cables TX in parallel finally insert them into the terminal and tighten the screws using a slotted screwdriver Note It is recommended to use two different wire colours to connect TX 485 and TX 485 Wires of the same colour can be connected together to avoid incorrect wire connections Figure 36 Connecting multiple inverters 4 6 Communication systems The 1...

Page 34: ...ata to be sent to the ZCS server Figure 36 Connecting an inverter with RS485 It is possible to connect up to 31 inverters in a daisy chain via the RS485 port The first in this series must then be connected to a terminal in the manner described above Figure 38 Connecting multiple inverters with RS485 Note 1 The RS485 communication cable must not be longer than 1000 m Note 2 When multiple inverters ...

Page 35: ...rs Figure 40 Connecting multiple inverters with Wi Fi To ensure proper transmission of the Wi Fi signal completely extract the Wi Fi antenna by following the procedure below 1 Loosen the cable gland of the Wi Fi antenna 2 Pull out the Wi Fi antenna for about 5 cm or until the cable gland prevents it from being pulled out any further 3 Tighten the cable gland of the Wi Fi antenna Figure 41 Extracti...

Page 36: ...rter is properly connected to the grid Check that the phase voltage is within the correct range If possible measure the THD if there is too much distortion the inverter may not operate properly 5 2 Starting the inverter 1 Turn ON the DC switch on the field panel and on the photovoltaic inverter if present wait for the screen to turn on 2 Turn ON the AC switch installed on the wall When the photovo...

Page 37: ...nd LED indicators Figure 42 LCD display with buttons and LED indicators Main buttons Menu Back to go back or enter the main menu Up to go up or increase the value by 1 Down to go down or decrease the value by 1 OK Enter to confirm the selection and enter the menus Indicator lights Status light GREEN o Flashing wait or status check o Steady normal operation o Off temporary or permanent error Warnin...

Page 38: ...n the main interface A1 Modbus communication address A2 RS485 Communication A3 Steady light for active RS485 communication A4 Wi Fi Communication A5 Flashing light to indicate over frequency and power derating status Steady light to indicate remote control A6 Indicates the energy produced today A7 Indicates the energy produced in total A8 Steady light to indicate the high temperature of the invert...

Page 39: ...herwise the inverter will go into an error state Check inverter is checking the insulation resistance relays and other safety parameters It also runs a self test to ensure that the software and hardware of the inverter are functional Inverter will go to an error state if any faults or anomalies are found Normal inverter is functioning properly and is feeding power into the grid If any faults are f...

Page 40: ... menu The Settings menu contains the following sub menu Date and time Select 1 Date and time and press OK to enter the menu for setting the date time First set the date and then the time using the Up and Down keys then press OK to move to the next character and confirm The date and time are expressed in the format 20YY MM DD HH MM SS The display will show OK if the setting is correct and Error in ...

Page 41: ...cessful Set Country Select 4 Set Country and press OK to enter the menu for setting the national grid connection regulations If Setting Disabled appears on the display go to step 7 Enable Country to enable this function After enabling the function repeat the steps described above and set the code for the desired country using the Up and Down keys confirming with OK the display will show OK if the ...

Page 42: ...ds its data to the monitoring server Address 01 is used for single inverters if you want to extend the monitoring to multiple inverters progressive communication addresses will be used Note make sure that the address entered is never 00 because this setting would exclude the possibility of communication between the inverter and Wi Fi network Language Select 10 Language and press OK to enter the me...

Page 43: ...one and confirm If the display shows Incorrect try again press the Back key and enter the password again When the password entered is correct you can enter the menu The new protection frequency will now be loaded on the inverter automatically If the setting is successful OK will be displayed otherwise Error will be displayed Attention do not enter this menu if the microSD card is not inserted in t...

Page 44: ...mount of energy to be produced the inverter will carry out the necessary operations to limit the output power to the set value If the setting is successful OK will be displayed otherwise Error will be displayed P GRID CHECK Select 18 P grid Check and press OK to enter the relative menu from which you can enable the Reflux Power function i e the possibility to set the maximum power fed into the gri...

Page 45: ...f 31 01 18 Application GID Manual of 07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL 4 Press OK to start the self test 5 The self test will now start automatically once completed press Down to display the self test results as shown in the figure ...

Page 46: ...07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL Standard Self test 1 During normal operation of the inverter press the Back key to enter the main menu 2 Press the OK key to enter the Settings menu 3 Press the Down key several times until 20 Standard Self Test is shown on the screen ...

Page 47: ...1 01 18 Application GID Manual of 07 06 2019 Rev 2 1 User Manual for 1 1K 3K TL 4 Press OK to start the self test 5 The self test will now start automatically once completed press Down to display the self test results as shown in the figure below ...

Page 48: ...f and press OK to enter the relative menu from which you can change the active power according to the grid frequency required by the local regulations This function may be required by various regulations for grid connected inverters Use the Up Down and OK keys to set the time delay expressed in seconds s before the changed P active power will intervene ...

Page 49: ...ommand relating to item 6 Relay Command Relay test relating to item 15 Relay Test cannot be used on this model of inverter access to these submenus is not permitted either by the installer or by the end user ZCS S p A accepts no responsibility deriving from the activation of one of the settings described above B Press the OK key to enter the Event List menu The Event List menu is used to display t...

Page 50: ...the country code that has been set Power factor Use the Up and Down keys in the System Info menu to move and the OK key to enter the 7 Power Factor menu Here you can see the value of the power factor P Grid Feed in Use the Up and Down keys in the System Info menu to move and the OK key to enter the 8 P Grid Feed in menu Here you can see the value of the set value of the power fed into the grid P f...

Page 51: ...s no microSD card inside the inverter or if the microSD card does not contain the appropriate update files Always make sure that the correct update files are loaded on the microSD card and that the card is correctly inserted in the appropriate slot Note the microSD card is not supplied with the inverter and must be procured by the installer or customer The complete and detailed procedure for updat...

Page 52: ...e on 8 From the display press the Menu Back key first from the left to enter the menu and then the OK key fourth from the left to enter the SOFTWARE UPDATE item Enter the password 0715 and press OK again to start the update 9 The update process will take about 3 minutes and will run automatically The following indications will be followed a DSP1 Update b DSP2 Update c ARM Update 10 Check that the ...

Page 53: ...y selection menu again set the country code according to the grid standard in your country e g CEI 021 INT CEI 021 EXT CEI 016 for Italy 14 Switch off the system and restart it after waiting a few minutes as indicated in step 13 15 The update procedure has now been completed and the inverter can now be connected to the AC line by connecting it to the grid The new firmware version can be checked fr...

Page 54: ...s Menu Back to enter the main menu from the standard interface Select Event List in the menu screen then press OK to access the list of alarms and errors Information on event list Error code Error name Error description Possible solution ID01 GridOVP The grid voltage is too high If the alarm occurs occasionally the probable cause is that the electric grid is in an abnormal state The inverter will ...

Page 55: ...he insulation conditions of the PV cables ID14 HwBoostOCP The input current is too high and has caused the hardware protection to be activated Check if the input current is higher than the maximum input current allowed by the inverter then check the input wiring if both are correct contact Technical Support ID15 HwAcOCP The grid current is too high and has caused the hardware protection to be acti...

Page 56: ... contact Technical Support ID49 ConsistentFault_VGrid The grid voltage sampling value between the master DSP and slave DSP is not the same ID49 ID55 are internal faults of the inverter turn off the DC switch wait 5 minutes and then turn it back on again Check that the fault is no longer present If this is not the case contact Technical Support ID50 ConsistentFault_FGrid The grid frequency sampling...

Page 57: ... Check that the fault is no longer present If this is not the case contact Technical Support ID66 UnrecoverBusOVP The bus voltage is too high and has caused an irreparable fault ID70 UnrecoverOCPInstant The grid current is too high and has caused an irreparable fault ID74 UnrecoverIPVInstant The input current is too high and has caused an irreparable fault ID74 ID77 are internal faults of the inve...

Page 58: ...ation of the country as indicated in Section 6 3 C 5 Country of this user manual if it is not correct change it according to Section 6 3 A 4 Configuration of country code of this manual ID98 Faulty SD The SD card is faulty Replace the microSD card ID99 ID100 Reserved Reserved 7 2 Maintenance Inverters generally do not require daily or routine maintenance In any case for proper long term operation ...

Page 59: ... end of its life dispose of the inverter and the packaging materials in places that can manage and recycle electrical equipment safely 9 Technical specifications Technical specifications 1100TL 1600TL 2200TL 2700TL 3000TL Input DC Typical power of PV system 1200W 1800W 2400W 2900W 3300W Number of MPPTs Number of strings per MPPT 1 1 Maximum DC input voltage 450V 500V Input activation voltage 100V ...

Page 60: ...ection Anti islanding RCMU Ground Fault Monitoring Safety certifications CE CGC AS47 77 AS3100 VDE4105 C10 Cll G83 G59 CEI 0 21 Grid connection standards AS 4777 AS3100 VDE AR N 4105 G83 G59 CEI 0 21 C10 11 Standard Safety standard IEC 62116 IEC 61727 IEC 61683 IEC 60068 1 2 14 30 IEC 62109 1 2 Grid connection standard AS 4777 VDE V 0124 100 VDE V 0126 1 1 VDE AR N 4105 EN50438 G83 2 C10 11 RD1699...

Page 61: ...es normal operation of the inverter If the inverter is defective or faulty during the warranty period contact your installer or supplier If the fault falls within the responsibility of the manufacturer Zucchetti Centro Sistemi S p A will provide service and maintenance free of charge Warranty exclusions Use of the 1 1K 3K TL inverters for any other purpose than the intended one Defective or faulty...