Danfoss DLX 2.0, DLX 2.9, DLX 4.6, DLX 3.8 Installation Manual
DLX
Installation Guide
DLX 2.0 - DLX 2.9 - DLX 3.8 - DLX 4.6
MAKING MODERN LIVING POSSIBLE
SOLAR INVERTERS
II Installation Guide DLX series L00410622-01
Danfoss can accept no responsibility for possible errors in catalogues, brochures
and other printed material. Danfoss reserves the right to alter its products without
notice.
This also applies to products already on order provided that such alterations can be
made without subsequent changes being necessary in specifications already
agreed.
All trademarks in this material are property of the respective companies. Danfoss
and the Danfoss logotype are registered trademarks of Danfoss A/S. All rights
reserved.
Copyright ©: Danfoss, 2012
Installation Guide DLX seriesL00410622-01 III
Contents
1. Product Overview ....................................................................................................... 4
1.1. Symbols Used ............................................................................................................................................ 4
1.2. Product Label ............................................................................................................................................. 4
2. Installation .................................................................................................................. 8
2.1 Safety Equipment Required for Grid Connected Systems .......................................................... 8
2.2. Mechanical Installation .......................................................................................................................... 9
2.3. Checks Prior to Installation ................................................................................................................. 12
2.4. Electrical Installation ............................................................................................................................. 13
2.5. Required Safety Equipment ................................................................................................................ 23
2.6. Checks before Start Up ......................................................................................................................... 24
3. Start Up ...................................................................................................................... 25
3.1. Initial Start ................................................................................................................................................. 25
3.2. Self Test for Italy ...................................................................................................................................... 36
4. Connection between Inverter and PC ..................................................................... 38
4.1. Without a Network ................................................................................................................................. 38
5. Internal Web Server .................................................................................................. 39
6. Troubleshooting ....................................................................................................... 40
6.1. Check List by Failure .............................................................................................................................. 40
6.2. Table of Events ........................................................................................................................................ 40
7. Maintenance and Disposal ....................................................................................... 44
7.1. Regular System Inspection ................................................................................................................. 44
8. Warranty .................................................................................................................... 45
8.1. Warranty Disclaimer .............................................................................................................................. 45
8.1.1. Damage .................................................................................................................................................. 45
8.2. End of Life Disposal ............................................................................................................................... 45
9. Technical Data ........................................................................................................... 47
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Installation Guide DLX series L00410622-01
1. Product Overview
This Installation Guide contains all the necessary install information to connect and start up
the DLX inverter. The inverter must be used in compliance with the DLX User Guide, which is
to be found at www.Danfoss.com.
1.1. Symbols Used
The warning symbols used in this Installation Guide highlight important information on
how to avoid shock hazards to equipment and persons. Pay particular attention when
the symbols appear!
Table 1.1: Warning symbols appearing in this guide
Symbol Description
DANGER:
Situations where an immediate hazard could cause serious injury or
death to workers and/or the general public if not avoided.
WARNING: Situations where a potentially hazardous condition exists that could
result in the death or serious injury of workers and/or the general public if not
avoided.
CAUTION: Situations where a non-immediate or potential hazard presents a
lesser threat of injury that could result in minor or moderate injuries to workers
and/or the general public.
NOTICE
: Situations where a non-immediate or potential hazard presents a risk
to damage of property and equipment. May be used to indicate important
operational characteristics. There is no Safety Alert or attention symbol present in
this situation.
1.2. Product Label
The product label contains important identification parameters and characteristics for the
inverter, and must be clearly visible after installation.
Figure 1.2.1: Product Label
Installation Guide DLX seriesL00410622-01
5
Table 1.2: Symbols appearing on the product label
Symbol Description
Discharge time: High voltages may be present inside the inverter for 1 hour after
switch OFF
Refer to User Guide: Look for further details in the User Guide, which is available
on the Danfoss website
Hot Surface: The heat sink on the back of the inverter can reach temperatures up
to 90 °C
Danger: High voltages are present
Disposal: Do not dispose in general waste! Collect the various parts separately
and recycle them according to local regulations
CE Marking: The product meets the EU safety, health and environmental
protection requirements
S – NO: Serial Number for inverter identification
1.3. Unpacking and Inspection
After unpacking the inverter safely, check that all components are present and in an
undamaged condition. If damaged, contact your supplier immediately!
1.3.1. Lifting and Carrying the Inverter
Considering the inverter’s weight of 20-22 kg, (depending upon model), lifting and
carrying the inverter must be correctly performed to prevent back injuries.
Figure 1.3.1: Correct lifting of the inverter
• When lifting, bend the knees, and keep
the back straight.
• Lift carefully; hold the inverter close to the
body and let the leg muscles do the work.
• Turn the whole body as one unit to avoid
twisting the lower back.
• Carry the inverter close to the body.
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Installation Guide DLX series L00410622-01
1.3.2. Unpacking
• Place the box in position, with the top clearly visible and according to the arrow marking
on the packaging.
• Cut the seal, and open the box.
• Take out the lock clip, the bag with accessories and the Installation Guide lying on the
upper section of the foam packaging material.
• Remove the upper part of the foam packaging material.
• Both sides of the inverter case are narrowed in order to get a
better grip on the device. Lift up the inverter carefully out of
the box using the “handles” illustrated in Figure 1.3.2.
• Remove the lower section of the foam packaging and take
out the inverter mounting bracket.
• Store all the original packaging for possible later reuse.
Figure 1.3.2: “Handles”
After unpacking the inverter safely, check that all components are present and in an
undamaged condition.
1.3.3. Scope of Delivery
• DLX single phase inverter
• Mounting bracket
• Installation Guide
• Accessories: grounding strap, bracket screws, lock clip, extra type label
NOTICE
The mating parts of the connectors are not part of the standard scope of supply,
and must be provided by the system installer.
1.3.4. Inverter Structure
The housing of the DLX series inverter is designed for indoor and outdoor use (IP65), and
provides a degree of protection from dirt, rain, sleet, snow, dust, water, and corrosion.
Figure 1.3.3: Mechanical dimensions
H: 610 mm
W: 353 mm
D: 158 mm
Installation Guide DLX seriesL00410622-01
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The front surface of the inverter consists of an upper and a lower cover.
The upper cover may only be removed by Danfoss authorized personnel. Removal of the
upper cover by unauthorized persons voids the warranty!
The lower cover protects the connection area, and may be removed by the system
installer for electrical connection and maintenance of the inverter.
Figure 1.3.4: Inverter structure
1. Upper cover
2. User Interface
3. Lower cover; customer connection area
4. AC output
5. DC input
6. Network input
DANGER
Always disconnect the PV array cables from the inverter after turning the AC and
DC OFF, but before removing the covers, as the PV array can supply up to 600 VDC
to the inverter when exposed to sunlight.
Fi
gure 1.3.5: Lower cover
• Loosen the four screws on the lower cover
with a 4 mm hex key, according to the
figure.
• Take the cover off carefully.
• Store the lower cover and screws safely to
avoid loss or damage.
• Fasten the screws on the lower cover with
a torque of 1.0 Nm.
CAUTION
Never remove the inverter lower cover in wet conditions! Removal of the inverter
lower cover during rain or in damp conditions can damage sensitive internal
electronic components.
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Installation Guide DLX series L00410622-01
2. Installation
The DLX inverters contain no user-serviceable parts, and installation and maintenance
must be performed by qualified persons, who have a qualified knowledge of the local
and national electrical regulations and who follow the instructions in this Installation Guide.
NOTICE
The DLX series is a grid interactive (grid-tie) inverter and must be used exclusively
for its designed purpose, which is to convert PV-generated DC electricity into AC
electricity to feed into the grid.
NOTICE
The DLX series require minimum 7W PV power and a DC voltage above 230V for
commissioning. An installation cannot be finished without 7W PV power. A small
DC power supply can be used.
• The inverter must be operated in its original and technically intact condition without any
unauthorized modifications.
• Always keep the values of operation within the limits given in the technical
specifications, due to the risk of possible inverter damage.
WARNING
The safety precautions and instructions in this Installation Guide must be read
thoroughly to be able to install and operate the inverter properly to prevent death,
injury or material damage.
2.1 Safety Equipment Required for Grid Connected
Systems
Ensure compliance with the local and national electrical regulations to satisfy the safety
equipment requirements.
NOTICE
The system installer is responsible for providing safety equipment that meets the
requirements for both the DC and AC operations, and to protect the equipment
and prevent personal injury, as per the local and national electrical regulations.
Installation Guide DLX seriesL00410622-01
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2.1.1. Disconnection Devices
Disconnection devices, switches or circuit breakers, enable a shut-off from the power
source during operation. They protect the current-carrying conductors and other system
components from power surges and system malfunctions, and help to shut down the
inverter safely for maintenance and repairs.
• Both AC circuit breaker(s) and DC switch(es) are recommended to facilitate maintenance
work and repairs of the inverter.
• The disconnect devices must conform to the local and national electrical regulations, and
have an interrupt rating sufficient for the voltage and current available in the circuit.
• Each disconnection device must be readily accessible and operable without exposing the
operator to live parts. All devices must be permanently marked for their purpose.
2.1.2. Overcurrent Protection Devices
Overcurrent protection devices, fuses or circuit breakers, prevent the circuit conductors
from overheating as a result of overload, short circuit or ground fault.
• An overcurrent protection device is required on every current carrying conductor.
• If a fuse blows or a circuit breaker trips the cause should always be determined before
replacing or resetting them.
• It is recommended to install an RCD (Residual Current Device) of type A between the AC
grid and the inverter, to be able to detect leakage current and interrupt fault paths. The
needed detection range must comply with the relevant local and national electrical
regulations!
2.2. Mechanical Installation
The mounting surface and the mounting method must be suitable for the inverter’s
weight, dimensions and possible housing temperature. This is crucial to maintaining the
efficiency of the inverter!
WARNING
Correct installation prevents the inverter from falling from the wall! The mounting
surface must be suitable for the weight 20-22 kg and temperature (90 °C) of the
inverter.
CAUTION
Protect the inverter from flammable and explosive environments, as the inverter
heat sink can reach temperatures up to 90 °C during long-periods of high
performance.
• The inverter is suitable for outdoor operation, but should be sheltered from direct
sunlight, snow, rain, dust and sand.
• Location should be in proximity to the PV arrays to minimize DC losses.
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Installation Guide DLX series L00410622-01
Avoid enclosed areas with poor air flow! Sufficient ventilation is needed to prevent
temperature build up inside the inverter and hence possible power losses. Observe the
minimum distances specified below to maintain optimal cooling:
Figure 2.2.1: Minimum distances for optimum cooling
1. 400 mm
2. 300 mm
3. 150 mm
4. 150 mm
For optimal operating conditions, the ambient temperature must be between
-25° C & +65° C, and non-condensing relative humidity between 4 % and 99 %.
NOTICE
Direct sunlight may cause yield losses, as direct sunlight causes increased internal
temperatures that can lead to reduced power output. Also, direct sunlight may
cause degradation of the LCD screen quality.
CAUTION
Ensure a location where people cannot accidentally come in contact with the rear
inverter surface, due to temperatures up to 90°C.
2.2.1. Wall Bracket
Depending on the mounting surface, different mounting methods may be required to
secure the wall bracket.
• The system installer is responsible for selecting the correct type and number of fixings
suitable to support the weight on the mounting surface.
• The bracket is designed to withstand 80 kg
• The inverter must be mounted in a vertical orientation.
• Keep the lower cover closed when mounting the inverter to avoid damage to internal
components.
• Mark the bracket holes on the mounting surface using a spirit level and the bracket as a
template to ensure the inverter is level.
• Fasten the bracket to the mounting surface with the required number of fixings to
support the hanging weight of the inverter.
Installation Guide DLX seriesL00410622-01 11
Figure 2.2.2: Inverter bracket
1. Carrier slots for the inverter
2. Steering slots for the inverter
3. Carrier slots for the Stringbox
4. Fixing clip
Figure 2.2.3: Distances between fixing screws
D1. 232.5 mm
D2. 232.5 mm
D3. 75 mm
D4. 75 mm
2.2.2. Inverter
Attach the inverter to the mounting bracket as follows:
Figure 2.2.4: Hooks on the back of the inverter
• Locate the hooks for the carrier
slots on the upper back and the
hooks for the steering slots on the
lower back of the inverter.
• Use the locating pins on the
Stringbox.
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Installation Guide DLX series L00410622-01
Figure 2.2.5: Mounting Inverter onto bracket
• Lift the inverter up and guide the
upper hooks into the slots on the
bracket.
• Control the lower hooks into the
slots and slide the inverter onto
the bracket.
• Ensure that the inverter is
correctly mounted, and tighten
the lock clip with one screw into
the inverter and one into the
Stringbox.
• Apply a torque of 1.0 Nm
2.3. Checks Prior to Installation
Make sure that the AC circuit breaker(s) and the DC switch(es) are OFF and that the
terminals are in a discharged state to prevent shock hazards.
DANGER
Contact with energized ports may cause lethal injuries! All installation of the
inverter must be performed with circuits de-energized!
All electrical installations shall comply with the local and national electrical regulations
in force at the installation site.
Check that the PV and the grid characteristics are compatible with the inverter
characteristics. Refer to 9. Technical Data
Check that the inverter is properly fastened and secured to the bracket.
Ensure that the conductors and circuit breakers/fuses are properly sized to comply with
the national electrical regulations.
Installation Guide DLX seriesL00410622-01
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Ensure that the conductors are listed for PV applications and the site environment, and
that they have the correct color coding.
2.4. Electrical Installation
Contact the local utility company for interconnection agreements and power approval
before connecting to the grid.
Correct electrical connection is critical for achieving a safe, long-term and reliable
operation of the entire PV system.
NOTICE
Only persons who are qualified to install high voltage electrical equipment and are
familiar with the electrical regulations applicable to the installation site may install
the inverter. This is to ensure a safe connection and avoid electrocution!
DANGER
Never work with live wires! All work on the inverter must be performed with
disconnected terminals, as contact with live wires may cause serious injury or
death!
2.4.1. Connection Area
The DC connections are achieved by the use of a Stringbox with DC switch and three sets
of DC connectors. The connection of the AC and the network cables are with screw
terminals and a RJ45 connector.
Figure 2.4.1: Stringbox with DC switch
1. CAN bus terminal
2. RS-485 terminal
3 Ethernet port
4. Internal DC terminal blocks, +POS
and -NEG
5. Internal DC ground receptacle,
GND/PE
6. Stringbox equipped with DC switch
7. Internal AC terminal block
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Installation Guide DLX series L00410622-01
2.4.2. Grounding
Appropriate grounding of the entire PV system limits voltage surges, gives a common
reference point for the conductive parts and facilitates the operation of the overcurrent
devices.
NOTICE
• Grounding must be carried out by qualified persons only and comply with local
and national electrical regulations.
• Follow the safety instructions and specifications from the different PV module
manufacturers regarding grounding requirements.
• The PV strings may be ungrounded, or grounded through either the negative or the
positive string conductors.
• The grounded DC conductors are connected to ground via the grounding strap.
• The grounded conductors must be sized according to the local and national electrical
regulations, and only carry current when electrical malfunctions occur.
• All metal parts of the DLX inverters are electrically bonded to ground through the
terminal labeled GND in the AC terminal block.
CAUTION
If the positive or negative PV conductors are grounded, then the grounding strap
must be connected to the DC ground terminal and the system must NOT be
grounded at any other point, as voltage potentials can appear and possibly
damage electrical components.
A minimum cross section area of 6.0 mm² / 10 AWG is required for the ground wire
connection.
2.4.3. DC Connections (PV)
The DC connections include wiring from the PV modules, through the combiner box, to
the inverter.
DANGER
Always disconnect the PV array before starting the connection on the DC side!
Charged DC terminals pose a risk of serious injury or death as the PV array can
supply up to 600 V
DC
to the inverter when exposed to sunlight.
WARNING
Never remove cables during operation! The inverter is charged with high voltages,
and removal of cables during operation may cause arcing
Installation Guide DLX seriesL00410622-01
15
NOTICE
Maximum Voltage: The open circuit voltage, V
OC
, must never exceed 600 VDC
under any conditions. The voltage generated by PV modules is inversely
proportional to the temperature; at lower temperatures the PV voltage increases
from the nameplate rating and at higher temperatures the PV voltage decreases
from the nameplate rating.
NOTICE
Ensure the DC switch in the Stringbox is in the OFF position, when removing the
lower cover to access the connection terminals.
Figure 2.4.4: DC switch
0 = OFF
I = ON
2.4.3.1. Stringbox with DC switch
The Stringbox is equipped with DC switch and plug-in connectors.
Figure 2.4.5: Optional DC connectors and DC switch
P1, P2, P3:
Positive connectors
N1, N2, N3:
Negative connectors
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